WARNING Indicates a strong possibility of severe personal ... · The symbols used through out this manual show specific service procedures. If supplementary information is required

WARNING Indicates a strong possibility of severe personal injury or death if instructions are not followed.CAUTION: Indicates a possibility of equipment damage if instructions are not followedNOTE: Gives helpful information.

service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which servicewhether or not recommended by manufacturer, might be done or of the possibly hazardous consequences ofeach conceivable way, nor could manufacturer investigate all such ways. Anyone using service proceduresor tools, whether or not recommended by manufacturer, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.

HOW TO USE THIS MANUAL C O N T E N T SThis service manual describes the service procedures for the Thumpstar Off Road Range GENERAL INFORMATION

Follow the Maintenance Schedule (Section 3) recommendations to FRAME/BODY PANELS/ EXHAUST SYSTEMensure that the vehicle is in peak operation condition and the emission levels are within the standards set by the California Air MAINTENANCEResources Board.

LUBRICATION SYSTEMPerforming the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period FUEL SYSTEM

Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates ENGINE REMOVAL/ INSTALLATIONwhat may be required to perform service described in the followingsections. Section 4 through 14 describe parts of the motorcycle, CYLINDER HEAD/ VALVESgrouped according to location.

CYLINDER/PISTONFind the section you want on this page, then turn to the table of contentson the first page of the section. CLUTCH/GEARSHIFT LINKAGE

Most sections have an assembly or system illustration , service ALTERNATOR/CAM CHAIN TENSIONERinformation and troubleshooting for the section.

CRANKSHAFT/TRANSMISSION/KICKSTARTERThe subsequent pages give detailed procedures. If you don't knowthe source of the trouble, go to section 16, troubleshooting CHASSIS FRONT WHEEL/BRAKE/SUSPENSION/STEERING

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATION REAR WHEEL/BRAKE/SUSPENSIONINCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. ELECTRICAL IGNITION SYSTEMTHUMPSTAR MOTOR INC RESERVES THE RIGHT TO MAKE CHANGESAT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY WIRING DIAGRAMOBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BEREPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN TROUBLESHOOTINGFOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OFMAINTENANCE ON MANUFACTURER'S MOTORCYCLES, INDEXMOTOR SCOOTERS OR ATVS. SERVICE PUBLICATION OFFICE

IMPORTANT SAFETY NOTICE

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific

ENGINE

ANDDRIVETRAIN

SYMBOLSThe symbols used through out this manual show specific service procedures. If supplementaryinformation is required it would be explained specifically inthe text without the use of the symbols.

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide,NLG#2

Example: Molykote BR-2 plus manufactured by Dow Corning, U. S. A. Multi-purpose M-2 manufactured by Mitsubishi oil, Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLG#2or equivalent).Example: Molykote G-N paste manufactured by Dow Corning, U.S.A. Manufacture Moly 610 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan.

1. GENERAL INFORMATIONGENERAL SAFETY----------------------------1-1 TOOLS-----------------------------------------------------1-12SERVICE RULES-------------------------------1-2 LUBRICATION & SEAL POINTS----------------------1-13MODEL IDENTIFICATION--------------------1-3 CABLE &HARNESS ROUTING------------------------1-14SPECIFICATIONS------------------------------1-4 EMISSION CONTROL SYSTEMS--------------------1-17TORQUE VALUES-----------------------------1-10

GENERAL SAFETYCARBON MONOXIDE HOT COMPONENTSIf the engine must be running to do some work ,makesure the area is well ventilated. Never run the engine WARNINGin an enclosed area. Engine and exhaust system parts become very hot and

remain hot for some time after the engine is run. WearWARNING insulated gloves or wait until the engine and exhaust system The exhaust contains poisonous carbon monoxide have cooled before handing these parts.gas that can cause loss of consciousness and maylead to death. USED ENGINE OIL

Run the engine in an open area or with an exhaust WARNINGevacuation system in an enclosed area. Used engine oil may cause skin cancer if repeatedly left

in contact with the skin for prolonged periods. Although GASOLINE this is unlikely unless you handle used oil on a dailyWork in a well ventilated area. Keep cigarettes, flames basis, it is still advisable to thoroughly wash your handsor sparks away from the work area or where gasoline with soap and water as soon as possible after handlingis stored. used oil. KEEP OUT OF REACH OF CHILDREN.

WARNINGGasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OFCHILDREN.

or equivalent)

Use silicone grease.

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

Use Fork or Suspension Fluid.

Apply sealant.

Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Replace the part (s) with new one (s) before assembly.

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1)

Use multi-purpose grease (Lithium based multi-purpose grease NLG1#2 or equivalent).

GENERAL INFORMATIONSERVICE RULES

1.Use genuine Manufacturer's recommended parts and lubricants or their equivalent. Partsthat do not meet Manufacturer's design specifications may cause damage to the motorcycle.2.Use the special tools designed for this product to avoid damage and incorrect assembly.3.Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws.4.Install new gaskets, O-ring ,cotter pins ,and lock plates when reassembling.5.When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torquediagonally in incremental steps unless a particular sequence is specified.6.Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.7.After reassembly, check all parts for proper installation and operation.8.Route all electrical wires as shown on pages 1-14 through 1-16, Cable and Harness Routing.

GENERAL

26。

Trochoid Foam StyleOiled polyurethane foam

FRAME

21kg (46.3lbs) Assembled type

Forced pressure and wet sump

Cylinder arrangement

125cc 52.4mmx57mm90cc= 86ml 110cc=107ml 125cc=122.7ml90cc 9.0 1 110cc 9.7.1 125cc 9.0.1Chain driven OHC with rocker arm7.5。BTDC12.5。ABDC22.5。BBDC2.5。BTDC

Oil pump type Air filtrationCrankshaft type

Intake valve opens at 1mm closes (0.04in)

closesLubrication system

3.0&(0.79 US gal, 0.66 lmp gal0.9&(0.24 US gal, 0.20 lmp gal)

Bore and stroke 90cc 47mmx49.5mm 110cc 52.4mmx49.5mm

Front/Rear: C-183A-3Internal expanding shoeInternal expanding shoe

35mm(1.4 in)

SwingarmConventional type oil damper 2.50-10/12/142.50/2.75/3.00-10/12

Caster angleTrail lengthFuel tank capacityFuel tank reserve capacity

Rear suspensionRear damperFront tyre sizeRear Tyre

Frame type Back bone Front suspension Telescopic fork

Overall LengthOverall widthOverall height WheelbaseSeat heightFoot peg heightGround clearanceDry weight

700mm27.6 in)

ENGINE

Exhaust valve opens lift

DisplacementCompression ratioValve train

Engine dry weight

SPECIFICATIONSITEM1,430mm(71.0 in)760mm(30.0 in)950mm(37.4 in)990mm(38.9in)

215mm(8.5 in)240mm(9.4 in)60 kg (180.8 lbs)

MODEL IDENTIFICATION

(2)The engine serial number is stamped on the lower left of the crankcase.

ENGINE SERIALNUMBER

(3)The vehicle identificationnumber (VIN) is located on theright side of the steering head.

VEHICLEIDENTIFICATION

Clutch system

4-speed

Ignition systemStarting system

SERVICE LIMIT

At draining 0.6(0.6US qt, 0.5lmp qt) -------------------At disassembly 0.8(0.8US qt, 0.7lmp qt) -------------------

GN4 4-stroke oil or equivalent Motor oil -------------------APL service classification SF or SGViscosity: SAE 10W-30

Tip clearance 0.15(0.006) 0.12(0.005)Body clearance 0.02-0.07(0.001-0.003) 0.12(0.005)Side clearance 0.10-0.15(0.004-0.006) 0.20(0.008)

FUEL SYSTEMITEM

Carburetor identification numberMain jetJet needle clip positioningAir screw initial opening Float levelIdle speedThrottle grip free play

Unit:mm(in)

ITEM SERVICE LIMIT

Cylinder compression 981-1, 177kpa (10.0-12.0kgf/cm 2,142-171jpsi)at 1,000 rpm

Cylinder head warpage 0.05(0.002)Valve clearance IN 0.05±0.02(0.002±0.001) --------------------

Valve, Valve guide EX 0.05±0.02(0.002±0.001) --------------------Valve stemO.D. IN 4.970-4.985(0.1957-0.1963) 4.92(0.194)

EX 4.955-4.970(0.1951-0.1957) 4.92(0.194)Valve guide I.D IN/EX 5.000-5.012(0.1969-0.1973) 5.03(0.198)

IN 0.015-0.042(0.0006-0.0017) 0.08(0.003)EX 0.030-0.057(0.0012-0.0022) 0.10(0.004)

Valve seat width IN/EX 1.0-1.3(0.04-0.05) 2.0(0.08)Valve spring free length IN/EX 33.34(1.313) 31.8(1.25)Rocker arm/Rocker arm I.D. IN/EX 10.000-10.015(0.3937-0.3943) 10.10(0.398)

Rocker arm shaftO.D. IN/EX 9.978-9.987(0.3928-0.3932) 9.91(0.390)IN 20.003-20.123(0.7875-0.7922) 19.66(0.774)EX 19.994-20.114(0.7872-0.7919) 19.65(0.774)

Unit:mm(in)

SERVICE ITEMCylinder I.D. THUMPSTAR 47.05(1.8524)

THUMPSTAR 52.45(2.650)Out of round 0.10(0.004)Taper 0.10(0.004)Warpage 0.05(0.002)Piston mark direction "IN"mark facing toward the intake side -----------------

Piston, Piston O.D. 38.975-38.995(1.5344-1.5352) 38.90(1.531)Piston O.D.measurement point 8mm(0.3in)from bottom of skirt -----------------Piston pin bore I.D. 13.002-13.008(0.5119-0.5121) 13.06(0.514)Piston pin O.D. 12.994-13.000(0.5116-0.5118) 12.98(0.511)Piston-to-piston pin clearance 0.002-0.014(0.0001-0.0006) 0.08(0.003)Piston ring-to-ring 0.015-0.050(0.0006-0.0020) 0.12(0.005)Groove clearance Top SecondPiston ring end gap Top 0.05-0.015(0.002-0.006) 0.5(0.02)

Second 0.05-0.20(0.002-0.008) 0.5(0.02) Oil(side rail) 0.3-0.9(0.01-0.04) 1.1(0.04)

Cylinder-to-piston clearance 0.010-0.040(0.0004-0.0016) 0.15(0.006)Connecting rod small end I.D. 132.016-13.034(0.5124-0.5131) 13.08(0.515)Connecting rod-to-piston pin clearance 0.016-0.040(0.0006-0.0016) 0.12(0.005)

Pistonrings

-------------------

STANDARD

---------------------------------------------------------

STANDARD

LUBRICATION SYSTEM

19mm(0.75in)1,500±100rpm

2.0-6.0mm(1/16-1/4in)

ITEM

Oil pump rotor

STANDARD

1-1/2turns out

SPECIFICATIONSVM22-38 VM16-486B

125cc= 95# #95=110cc #85=90cc 4th groove from top (Different in each country)

LUBRICATION SYSTEM

Engine oil capacity

Recommendedengine oil

CARBURETOR

DRIVE TRAIN

ELECTRICAL

Primary reductionFinal reduction

CDI (Capacitive Discharge lgnition)Kickstarter and electric

Final reduction

Multi-plate, wetAutomatic centrifugal

4.059(69/17)2.866(37/14)1.706(36/11)

Clutch operation systemTransmission

SPECIFICATIONSCarburetor typeThrottle bore

Piston valveITEM

Stem to guide clearance

Cam lobe height

GENERAL INFORMATION

CYLINDER HEAD/VALVES

ITEM

Camshaft

Unit:mm(in)

ITEM SERVICE LIMITClutch disc thickness 2.52-2.68(0.099-0.106) 2.3(0.09)

3.32-3.48(0.131-0.137) 3.0(0.12)Clutch plate warpage 0.20(0.008)Centrifugal clutch spring free length 22.4(0.88) 19.4(0.76)Primary drive gear I.D. 21.000-21.021(0.8268-0.8276) 21.05(0.829)Clutch centre guide 16.988-17.006(0.6688-0.6695) 17.04(0.671)

20.930-20.950(0.8240-0.8248) 20.90(0.823)Crankshaft O.D. at clutch centre guide 16.966-16.984(0.6680-0.6687) 16.90(0.665)

Unit:mm(in)

ITEM SERVICE LIMITCam chain tensioner 11.94(0.470)

100(3.9)

CRANKSHAFT/TRANSMISSION/KICKSTARTERITEM SERVICE LIMIT

Crankshaft Side clearance 0.60(0.024)Radial clearance 0.05(0.002)Run out 0.10(0.004)Gear I.D. M2 17.10(0.673)

C1 23.10(0.909)C3 20.10(0.791)

TransmissionBushing O.D. C1 22.93(0.903)Bushing I.D. C1 20.08(0.791)Gear-to-bushing clearance C1 0.10(0.004)Mainshaft O.D. M2 16.95(0.667)Countershaft O.D. C1 19.94(0.785)Gear-to-shaft clearance M2 0.10(0.004)Gear bushing-to-shaft clear C1 0.10(0.004)

Shift fork I.D 34.14(1.344)Claw thickness 4.60(0.181)Shift drum O.D. 33.93(1.336)

Unit:mm(in)

FRONT WHEEL/BRAKE/SUSPENSION/STEERING

ITEM SERVICE LIMITMinimum tyre tread depth 3.0(0.12)

175kpa(1.75kgf/cm 2,26.25psi)Axle run out 0.20(0.008)Wheel rim ru

2.0(0.08)Brake 2.0(0.08)Fork 373.5(14.70)

Unit:mm(in)

ITEM SERVICE LIMITMinimum tyre tread depth 3.0(0.12)Cold tyre pressure 175kpa(1.75kgf/cm 2,29.25psi) --------------------Axle run out 0.20(0.008)

--------------------Wheel rim run out Radial 2.0(0.08)Drive chain Axial 2.0(0.08)Brake Size/Link DlD420MBK1/88 --------------------

Slack 15-25(9/16-1) --------------------Brake pedal free play 10-20(3/8-13/16) --------------------

ITEMSpark plug Standard CR6HSA(NGK) U20FSR-U(DENSO)

For cold climate/below41oF/50C CR5HSA(NGK) U16FSR-U(DENSO)For extended high speed riding CR7HSA(NGK) U22FSR-U(DENSO)

Spark plug gapIgnition coil peak voltageIgnition coil generator peak voltageAlternator exciter coil peak voltageIgnition timing ("F" mark)

0.7Vminimum100Vminimum15.BTDC at idle

--------------

SPECIFICATIONS

0.60-0.70mm(0.024-0.028in)100Vminimum

STANDARD--------------

--------------

--------------

376(14.8)

RadialAxialBrake lever free playSpring free length

----------------------------

STANDARD

10-20(3/8-13/16)

--------------

4.86-4.94(0.191-0.194)33.950-33.975(1.3366-1.3376)

19.959-19.980(0.7858-0.7866)0.032-0.077(0.0013-0.0030)0.020-0.062(0.008-0.0024)34.075-34.100(1.3415-1.3425)

0.020-0.074(0.0008-0.0029)16.966-16.984(0.6680-0.6687)

17.016-17.043(0.6699-0.6710)

0-0.012(0-0.0005)

23.020-23.053(0.9063-0.9076)20.020-20.053(0.7882-0.7895)22.979-23.000(0.9047-0.9055)20.000-20.021(0.7874-0.7882)

----------------------

0.010-0.350(0.0004-0.0138)

111.3(4.38)

STANDARD

STANDARD11.985-12.000(0.4718-0.4724)

B

I.D.O.D.

STANDARD

Spring free lengthPush rod O.D.

ALTERNATOR/CAM CHAIN TENSIONER

A

CLUTCH/GEARSHIFT LINKAGE

Cold tyre pressure

REAR WHEEL/BRAKE/SUSPENSION

STANDARDTORQUE TORQUE

N.m(kgf:m,ibf.ft)4(0.4,2.9)

5mm hex bolt and nut 5(0.5,3.6) 9(0.9,6.5)6mm hex bolt and nut 10(1.0,7) 10(1.0,7)8mm hex bolt and nut 22(2.2,16) 12(1.2,9)10mm hex bolt and nu34(3.5,25) 12(1.2,9)12mm hex bolt and nu54(5.5,40) 26(2.7,20

39(4.1,29)Torque specifications listed below are for important fasteners.Others should be tightened to standard torque values listed above.NOTES:1.Apply oil to the threads. 2.Apply grease to the seating surface. 3.U-nut. 4.ALOC bolt; replace with a new one.

ENGINEITEM TORQUE

N.m(kgf.m,lbf.ft)MAINTENANCE: Spark plug 1 10 12(1.2,9) Oil drain bolt 1 12 25(2.5,18) Valve adjuster hole cap 2 30 12(1.2,9) NOTE1 Valve adjuster lock nut 2 5 9(0.9,6.5) Clutch adjuster lock nut 1 8 12(1.2,9)LUBRICATION SYSTEM: Oil pump mounting screw 3 6 8(0.8,5.8) Oil pump cover screw 3 5 5(0.5,3.6)ENGINE REMOVAL/INSTALLATION; Drive sprocket fixing plate bolt 2 6 12(1.2,9)CYLINDER HEAD/VALVES; Cylinder head nut 4 6 11(1.1,8) Cylinder head right side cover bolt 2 6 10(1.0,7) Cam sprocket bolt 2 5 9(0.9,6.5)CYLINDER/PISTON: Cam chain guide roller pin bolt 1 8 10(1.0,7)CLUTCH/GEARSHIFT LINKAGE: Clutch outer cover screw 4 5 5(0.5,3.6) Clutch lock nut 1 14 42(4.3,31) Clutch assembly screw 4 5 6(0.6,4.3) Shift drum stopper arm bolt 1 6 13(1.3,9) Shift return spring pin 1 8 29(3.0,22)Gearshift cambolt 1 6 17(1.7,12)ALTERNATOR/CAM CHAIN TENSIONER Flywheel nut 1 10 41(4.2,30) Cam chain tensioner sealing bolt 1 14 23(2.3,17) Cam chain tensioner pivot bolt 1 8 16(1.6,12)CRANKSHAFT/TRANSMISSION/KICKSTARTER Shift drum bolt 1 6 12(1.2,9)

REMARKSQ'TY THREAD DIAMETER (mm)

TORQUE VALUES

FASTENER TYPE N.m(kgf:m,ibf.ft)

ITEM TORQUEN.m(kgf-m,lbf.ft)

FRAME/BODY PANELS/EXHAUST SYSTEM Side stand pivot bolt 1 ---- Page 2-5 Muffler mounting bolt 1 26(2.7,20) Exhaust pipe protector bolt 3 15(1.5,11) Exhaust pipe cover screw 4 6(0.6,4.3)MAINTENANCE: Fuel valve mounting bolt 2 9(0.9,6.5)FUEL SYSTEM: Connecting tube band screw 1 1(0.1,0.7)ENGINE REMOVAL/INSTALLATION: Engine hanger nut 2 31(3.2,23)FRONT WHEEL/BRAKE/SUSPENSION/STEERING: Handlebar mounting nut 2 20(2.0,14)Engine stop switch/throttle housing screw 2 3(0.3,2.2)Brake lever pivot bolt 1 3(0.3,2.2)Brake lever pivot nut 1 3(0.3,2.2) Spoke nipple 28 2(0.2,1.4) Front axle nut 1 12 47(4.8,35) NOTE 3 Front brake arm pinch bolt 1 5 6(0.6,4.3) NOTE 4 Fork protector bolt 4 6 10(1.0,7) Steering stem nut 1 22 74(7.5,54) Steering stem top thread 1 22 ---- Page 12-17REAR WHEEL/BRAKE/SUSPENSION Spoke nipple 28 2(0.2,1.4) Rear axle nut 1 12 47(4.8,35) NOTE 3 Driven sprocket nut 4 8 32(3.3,24) NOTE 3 Rear brake arm pinch bolt 1 5 6(0.6,4.3) NOTE 4 Swingarm pivot nut 1 10 39(4.0,29) NOTE 2,3Shock absorber mounting nut 2 10 34(3.5,25) NOTE 3 Drive chain slider nut 1 12(1.2,9) NOTE 3IGNITION SYSTEM Ignition coil mounting bolt 1 6(0.6,4.3)

TOOLS

NOTES:1.Equivalent commercially available in U.S.A 2.Not available in U.S.A 3.Alternative tool.

Carburetor float level gauge 5 Spoke wrench, 4.1x4.5mm NOTE1 3,12,13 Pin spanner 12 Valve adjusting wrench,8x9mm NOTE1 3 Valve adjuster B NOTE3 07908-KE90200(U.S.A.only) 3 Lock nut wrench,20x24mm 9 Extension bar NOTE1 9 Universal holder 10 Flywheel holder NOTE1 9 Attachment, 31x35mm 12,13 Attachment, 37x40mm 11,12 Pilot,12mm 12,13 Pilot,17mm 11 Bearing remover shaft NOTE1 12,13 Bearing remover head,12mm NOTE1 12,13 Drive 11,12,13 Valve spring compressor 7 Valve seat cutter NOTE1 7 Seat cutter,24mm(45。IN）

Seat cutter,20.5mm(45。EX） Flat cutter,24mm(32。IN) Flat cutter,21.5mm(32。EX) Interior cutter,22mm(60。IN/EX) Cutter holder,5mm Flywheel puller NOTE2,3:07933-0010000 10 Valve guide driver,5.0mm 7 Ball race remover 12 Steering stem driver NOTE3:07946-MB00000 12 Valve spring compressor attachment 07946-GC4000A(U.S.A.only) Valve guide reamer.5.0mm 7

NOTE3:07984-MA6000C 7 Peak voltage adaptor NOTE3:Peak voltage tester 14

5

6

BC2.3

TOOL NUMBER REMARKS REF.SEC

07401-001000007701-002010007702-0020001

6

4

8

5

BC2.3

8555

REMARKS

FRAME

THREAD DIAMETER (mm)QTY

1086

07708-003010007708-003040007716-002010007716-002050007725-003000007725-004000007746-001010007746-001020007746-004020007746-004040007746-005010007746-005030007749-001000007757-0010000

07780-001060007780-001100007780-001250007780-001280007780-0014202

07984-MA60001

07781-001040007933-GE0000

07948-MA6000007944-1150001

DESCRIPTION

07946-GC40000

07959-KM30101

07HGJ-0020100

LUBRICATION AND SEAL POINTS

Cylinder bore surfaceValve adjuster hole cap threadsConnecting rod small end bearingConnecting rod small end inner surfacePiston outer surface, piston pin hole and ring groovesPiston pin outer surfaceValve stem sliding surfaceCamshaft lobes Cam chainCam chain guide roller inner surfaceRocker arm inner and slipper surfacesCam chain tensioner push rod(inside)Oil pump rotorsClutch centre guide (whole surfaces)Clutch discsPrimary drive gear teeth and inner surfacePrimary driven gear teethMainshaft sliding surfaceCountershaft sliding surfaceTransmission gear sliding surface, gear teethand shifter grooveShift drum outer surfaceKickstarter spindle sliding surfaceOther rotating and sliding areaEach bearing rotating areaEach oil seal lipsEach O-ring

FRAME

REMARKSAir cleaner housing cover mating grooveThrottle grip pipe flangeSteering head bearing and race sliding surfaceWheel hub dust seal lipsWheel bearing cavitiesBrake panel anchor pin sliding surfaceBrake cam spindle and sliding surfacesBrake pedal pivotFork dust seal lipsFork slider outer surface(slider guide sliding surface) Apply5-6gFork slider guide outer groove Apply5-6gFork spring whole surface Pack with 14gSwingarm pivot nut seating surfaceSide stand pivot and sliding surfaceBrake cam dust sealThrottle cable outer insideBrake cable outer insideHandlebar grip rubber insideAir cleaner connecting tube-housing mating area

REMARKS

Engine oil

Pour 1-2cm3

Fill with 1-2cm3(page 10-6) Fill with 0.5-1cm3

Multi-purpose greaseMATERIAL

MATERIAL

Cable lubricant

MANUFACTURE bond A or equivalent

LOCATION

LOCATION

Engine oil

ENGINE

CABLE & HARNESS ROUTING

BRAKE CABLETHROTTLE CABLE

FUEL TANK BREATHER TUBE

ENGINE STOP SWITCHWIRE

FUEL TUBE

THROTTLE CABLE BRAKE CABLE

IGNITION COIL

THROTTLE CABLE

SPARK PLUG WIRE

ENGINE STOP SWITCH WIREIGNITIONSWITCHWIRE

THROTTLE CABLE

ALTERNATOR WIRE

CARBURETOR DRAIN TUBE

CLAMP

EMISSION CONTROL SYSTEMS

The California Air Resources Board (CARB) requires manufacturers to certify that their motorcycles complywith applicable exhaust emissions standards during their useful life, when operated and maintained accordingto the instructions provided.

SOURCE OF EMISSIONSThe combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight, Carbon monoxide does not react in the same way, but it is toxic.

Manufacturer Motor Co.,Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.

EXHAUST EMISSION CONTROL SYSTEMThe exhaust emission control system is composed of a lean carburetor setting, and no adjustments shouldbe made except idle speed adjustment with the throttle stop screw. The exhaust emission control system isseparate from the crankcase emission control system.

2.FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION---------------------2-1 NUMBER PLATE--------------------------------2-3

TROUBLESHOOTING-------------------------2-1 FRONT FENDER-------------------------------2-3

SEAT------------------------------------------------2-2 EXHAUST SYSTEM------------------------------2-4

FUEL TANK-----------------------------------------2-3 SIDE STAND-------------------------------------2-5

SERVICE INFORMATIONWARNINGGasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.Serious burns may result if the exhaust system is not allowed to cool before components are removed orserviced.

Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.This section covers removal and installation of the body panels, fuel tank and exhaust system.Always replace the exhaust pipe gasket after removing the exhaust system from the engine.When installing the exhaust system, loosely install all of the fasteners. Always tighten the exhaust pipe joint nuts first, then tighten the mounting. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.Always inspect the exhaust system for leaks after installation.

TORQUE VALUESSide stand pivot bolt see page2-5Muffler mounting bolt 26N.m(2.7kgf.m,20lbf.ft)

TROUBLESHOOTINGExcessive exhaust noiseBroken exhaust systemExhaust gas leakPoor performanceDeformed exhaust systemExhaust gas leakClogged muffler

FRAME/BODY PANELS/EXHAUST SYSTEM

SEATREMOVALRemove the two bolts.Remove the two screws and bolts.Pull the seat assembly back and remove it

INSTALLATIONInstall the seat assembly by inserting the prongs into the retainers on the frameInstall the bolts and screws and tighten them Install the bolts and lock themby pushing the centre pin flush.

DISASSEMBLY/ASSEMBLY


FUEL TANK

WARNINGGasoline is extremely flammable and is explosiveunder certain conditions. KEEP OUT OF REACH OFCHILDREN.

Remove the seat assembly(page2-2)

Remove the breather tube from the number plate.Turn the fuel valve OFF and disconnect the fuel tube fromthe fuel valve.

Remove the two bolts, washer and collarRemove the fuel tankInstallation is in the reverse order of removal.For fuel strainer service.see page3-4

NUMBER PLATERemove the breather tube from the number plate.Remove the fender mounting bolt.Remove the number plate from the steering stem nut andfront fender.Installation is in the reverse order of removal.

SEAT ASSEMBLY

BOLTS

SCREW

BOLTS

PRONGS

RETAINERS

TANK SHROUDS SCREWS

REAR FENDERSEAT

BOLT, RUBBER AND COLLAR

FUEL TANK

NUMBER PLATE

BOLT

FRONT FENDERRemove the three bolts and the front fender,Installation is in the reverse order of removal.

EXHAUST SYSTEM

WARNINGSerious burns may result if the exhaust system is notallowed to cool before components are removed orserviced.

REMOVAL INSTALLATION

Remove the seat assembly (page2-2) Install a new joint gasket into the exhaust port.Set the exhaust pipe onto the engine by aligning the

Remove the exhaust pipe joint nuts. exhaust pipe flange with the cylinder head studs, Remove the mounting bolt and the muffler. then install the joint nuts and the mounting bolt.Remove the exhaust pipe joint gasket.

Tighten the joint nutsFor spark arrestermaintenance, Tighten the mounting boltrefer to page3-17

TORQUE:26N.m(2.7kgf.m,20lbf.ft)

Install the seat assembly(page2-2)

MOUNTING BOLT 26N.m(2.7kgf.m,20lbf.ft)

SIDE STANDREMOVALSupport the motorcycle securely with a hoist or equivalent.

Retract the side stand and remove the following:-return spring-pivot nut-pivot bolt-side stand

INSTALLATIONApply grease to the side stand pivot and sliding surfaces.Install the side stand with the pivot bolt.

Tighten the pivot bolt.

TOROUE:10N.m(1.0kgf.m,7lbf.ft)

Loosen the pivot bolt 45-90.Install the pivot nut and tighten it while holding the pivot bolt.

Install the return spring as shown.

Check the side stand operation for freedom of movement.



GASKET

JOINT NUTS

NUT AND BOLT

SPRINGSIDE STAND

GREASE

SERVICE INFORMATION--------------------3-1 ENGINE IDLE SPEED----------------------3-11MAINTENANCE SCHEDULE------------------3-3 DRIVE CHAIN---------------------------------3-12FUEL LINE---------------------------------------3-4 DRIVE CHAIN SLIDER---------------------3-14THROTTLE OPERATION--------------------3-4 BRAKE SYSTEM----------------------------3-16AIR FILTER------------------------------------3-5 CLUTCH SYSTEM--------------------------3-16SPARK PLUG-----------------------------------3-6 SIDE STAND---------------------------------3-16VALVE CLEARANCE--------------------------3-7 SUSPENSION-------------------------------3-17ENGINE OIL--------------------------------------3-8 WHEELS/TYRES----------------------------3-18ENGINE OIL STRAINER SCREEN---------3-10 STEERING HEAD BEARINGS-----------3-18ENGINE OIL CENTRIFUGAL FILTER -----3-10

SERVICE INFORMATIONGENERAL

WARNINGGasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area.Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion.When the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation systemin an enclosed area.

Place the motorcycle on a level ground before starting any work.

SPECIFICATIONSITEM

Standard CR6HSA(NGK) U20FSR-U(DENSO)For cold climate/below41f/5C CR5HSA(NGK) U16FSR-U(DENSO)For extended high speed riding CR7HSA(NGK) U22FSR-U(DENSO)

ITEM Engine oil capacity At draining

At disassembly Recommended engine oil

Engine idle speed Throttle grip free play Valve clearance IN

EX Drive chain slack 15-25mmmm(5/8-1in) Drive chain size/link DID420MBK1/78 Brake lever free play 10-20mm(3/8-1313/16in) Brake pedal free play 10-20mm(3/8-1313/16in)TORQUE VALUESFuel valve mounting bolt 9N.m(0.9kgf.m, 6.5ibf/ft)Spark plug 12N.m(1.2kgf.m,9ibf.ft)Valve adjuster hole cap 12N.m(1.2kgf.m,9ibf.ft)Apply engine oil to the threadsValve adjuster lock nut 9N.m(0.9kgf.m,6.5ibf.ft)Oil drain bolt 25N.m(2.5kgf.m,18ibf.ft)Clutch adjuster lock nut 12N.m(1.2kgf.m,9ibf.ft)Rear axle nut 47N.m(4.8kgf.m,35ibf.ft) U-nut

TOOLSValve adjusting wrench,8x10mm 07708-0030100 Equivalent commercially available in U.S.AValve adjuster B 077087-0030400 or 07908-KE90200(U.S.A.only)Spoke wrench,4.1x4.5mm 07701-0020100 Equivalent commercially available in U.S.A.

Clutch adjuster lock nut 12N.m(1.2kgf.m,9ibf.ft)Rear axle nut 47N.m(4.8kgf.m,35ibf.ft) U-nut

SPECIFICATIONS

3.MAINTENANCE

Spark plug

SPECIFICATIONS

MANUFACTURE GN4 4-stoke oil or equivalent motor oil

0.6L(0.6US qt,0.5lmp qt)0.8L(0.8US qt, 0.7lmp qt)

MAINTENANCE

APL service classification SF or SG

0.05+0.02mm(0.002+0.001in)

Viscosity: SAE 10W-301,500+100rpm2.0-6.0mm(1/16-1/14in)0.05+0.02mm(0.002+0.001in)

MAINTENANCE SCHEDULEPerform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.1:lnspect and Clean, Adjust, Lubricate or replace if necessary.C:Clean R:Replace A:Adjust L:Lubricate

FREQUENCY

ITEMSRefer WHICHEVER INITIALto COMES FIRST MAINTENANCEpage MI 100

KM 150NOTE MONTH 1

3-4 FUEL LINE3-4 THROTTLE OPERATION3-5 AIR CLEANER NOTE13-6 SPARK PLUG3-7 VALVE CLEARANCE 13-8 ENGINE OIL R3-10 ENGINE OIL STRAINER SCREEN3-10 ENGINE OIL CENTRIFUGAL FILTER3-11 ENGINE IDLE SPEED 13-12 DRIVE CHAIN NOTE1 1,L

3-14 DRIVE CHAIN SLIDER3-14 BRAKE SHOES WEAR3-14 BRAKE SYSTEM 13-14 CLUTCH SYSTEM 13-16 SIDE STAND3-16 SUSPENSION3-17 SPARK ARRESTER C:Every 1000mi(1600km)or

Every 100 operating hours3-18 NUTS,BOLTS,FASTENERS 13-18 WHEELS/TYRES 13-19 STEERING HEAD BEARINGS 1

Should be serviced by your dealer,unless the owner has proper tools and service data and is mechanically qualified.In the interest of safety, we recommend these items be serviced only by your dealer.NOTEService more frequently when ridden in wet or dusty conditions.

FUEL LINECheck the fuel line for deterioration, damage or leakage.Replace the fuel line if necessary.

FUEL STRAINER SCREENWARNINGGasoline is extremely flammable and is explosiveunder certain conditions. Work in a well ventilatedarea. Smoking where the gasoline is stored cancause a fire or explosion.Wipe spilled gasoline at once.

Turn the fuel valve OFF and disconnect the fuel tube.Place a drain pan under the fuel tube and turn the fuelvalve ON to drain the fuel tank.After the tank has drained completely, remove the two bolts and collars, and remove the fuel valve and strainerscreen.

Wash the fuel strainer screen in non-flammable or highflash solvent.

Check the O-ring is in good condition, reinstall the fuelvalve.Tighten the fuel valve mounting bolts to the specifiedtorque.

TORQUE:9N.m(0.9kgf.m,6.5lbf.ft)After installation, check for fuel leaks.

MAINTENANCE

MAINTENANCE

FUEL LINEAIR FILTER

BOLTS AND COLLARS

FUEL VALVE

O-RING

STRAINERSCREEN

THROTTLE OPERATIONCheck for smooth throttle grip full opening and automaticfull closing in all steering positions.Check the throttle cable and replace it ,if it is deteriorated,kinked or damaged.Lubricate the throttle cable ,if throttle operation is not smooth.Measure the free play at the throttle grip flange.FREE PLAY:2.0~4.0mm(1/16~3/16 in)

Throttle grip free play can be adjusted at the upper endof the throttle cable.

Remove the dust cover from the adjuster.Adjust the free play by loosening the lock nut and turningthe adjuster.Tighten the lock nut and install the dust cover properly

Recheck the throttle operation.

AIR FILTER

SPARK PLUGREMOVALDisconnect the spark plug cap.Remove the spark plug using a spark plug wrench oran equivalent.Inspect or replace as described in the maintenanceschedule(page3-3)Clean around the spark plug base with compressed airbefore removing. and be sure that no debris is allowedto enter the combustion chamber.

INSPECTIONCheck the following and replace if necessary(recommended spark plug:page3-1)Insulator for damageElectrodes for wearBurning condition-dark to light brown indicates good condition.-excessive lightness indicates malfunctioning ignitionsystem or lean mixture.-wet or black sooty deposit indicates over-rich mixture

REUSING A SPARK PLUGClean the spark plug electrodes with a wire brush orspecial plug cleaner.Check the gap between the center and side electrodeswith a wire type feeler gauge.If necessary, adjust the gap by bending the side electrode carefully.SPARK PLUG GAP:0.6-0.7mm(0.024-0.028 in)

MAINTENANCE

MAINTENANCE

2.0-4.0 mm (1/16-3/16 in)

ADJUSTER LOCK NUT

DUST COVER

AIR FILTER

FUEL TUBE

PLUG CAP

CENTER ELECTRODE

SIDE ELECTRODE

INSULATOR

0.6-0.7mm( 0.024-0.028 in )

CAUTION:To prevent damage to the cylinder head, hand tightenthe spark plug before using a wrench to tighten to thespecified torque.

Reinstall the spark plug in the cylinder head and hand tighten, then torque it using a spark plug wrench.

TORQUE:12N-m(1.2kgf.m,9lbf.ft)

REPLACING A SPARK PLUGSet the plug gap to specification with a wire type feelergauge see previous page).

CAUTION:DO not over tighten the spark plug.

Install and hand tighten the new spark plug, then tightenit about 1/2 of a turn after the sealing washer contactsthe seat of the plug hole.

Install the spark cap.

VALVE CLEARANCEINSPECTIONRemove the valve adjuster hole caps.

Inspect and adjust the valve Clearance whileThe engine is cold(below 95 F/35C)

Remove the left crankcase cover(page10-2).

Turn the crankshaft counterclockwise and align the "T"mark on the flywheel with the index notch on the leftcrankcase.Mark on the flywheel with the index notch on the leftcrankcase.Make sure the piston is at TDC (Top Dead Center) on the compression stroke.This position can be obtained by confirming that thereis slack in the rocker arm.If there is no slack, rotate the crankshaft one full turncounterclockwise and match up the "T" mark again.

Check the valve clearance by inserting a feeler gaugebetween the valve adjusting screw and valve stem.VALVE CLEARANCEIN/EX:0.05 0.02MM(0.002 0.001IN)

ADJUSTMENT

Adjust by loosening the lock nut and turning the adjustingscrew until there is a slight drag on a feeler gauge.Hold the adjusting screw and tighten the nut.TOOLS:Valve adjusting wrench,8x9mm 07708-0030100 (equivalent commercially available in U.S.A)Valve adjuster B 07708-0030400 or 07908-KE90200

TORQUE:9.N.m(0.9kgf.m,6.5lbf.ft)

Recheck the valve clearance.

Check the valve adjuster hole cap O-ring is in goodcondition, replace if necessary.Coat the O-ring with clean engine oil and install themin the valve adjuster hole caps.Apply clean engine oil to the threads. Install and tightenthe valve adjuster hole caps to the specified torque.

MAINTENANCE

MAINTENANCE

PLUG CAP

SPARK PLUG LEAD

ADJUSTERVALVE CAPS

INDEX NOTCH

"T" MARK

ADJUSTER

CAP

O-RING

TORQUE:12N.m(1.2kgf-m,9lb.ft)

Install the left crankcase cover (page 10-8).

ENGINE OILOIL LEVEL INSPECTIONSupport the motorcycle in an upright position on levelground.Remove the oil filler cap/dipstick and wipe it clean.Check the oil level by inserting the oil filler cap/dipstickinto the oil filler hole without screwing it in.

The engine contains a sufficient amount of oil if the oillevel is between the upper and lower level marks on the dipstick.

If the level is near or below the lower level mark, fill with therecommended oil up to the upper level mark.

RECOMMENDED ENGINE OIL: 4-stroke oil or equivalent motor oil APL service classification:SF or SG Viscosity 10W-30

NOTE:Other viscosities shown in the chart may be used whenthe average temperature in your riding area is within theindicated range.

Reinstall the filler cap/dipstick.ENGINE OIL CHANGE

WARNINGWhen the engine must be running to do some work,make sure the area is well-ventilated . Never run theengine in an enclosed area. The exhaust containspoisonous carbon monoxide gas that may cause lossof consciousness and lead to death. Run the engine inan open area or with an exhaust evacuation systemin an enclosed area.Warm up the engine

Stop the engine and remove the oil filler cap/dipstick anddrain bolt.Drain the oil completely.

Used oil may cause skin cancer if repeatedlyleft in contact with the skin for prolonged periods.Although this is unlikely unless you handle used oilon a daily basis. It is still advisable to thoroughlywash your hands with soap and water as soon aspossible after handling used oil. KEEP OUT OF REACHOF CHILDREN.

Check that the sealing washer on the drain bolt is in goodcondition, replace if necessary.Install and tighten the drain bolt.

TORQUE:25N.m(2.5kgf-m,18lbf.ft)

Fill the crankcase with recommended engine oil(page3-8)

OIL CAPACITY: 0.6L(0.6USqt,0.5lmp qt) at draining 0.8L(0.8USqt,0.7lmp qt) at disassembly

Install the oil filler cap/dipstick

Start the engine and let it idle for 2 to 3 minutes.Stop the engine and recheck the oil level.Make sure there are no oil leaks.

MAINTENANCE

MAINTENANCE

OIL FILLER CAP/DIPSTICK

UPPER

LOWERED

OIL FILLER CAP/DIPSTICK

DRAIN BOLT AND WASHER

WASHER

DRAIN BOLT

ENGINE OIL STRAINER SCREENCLEANINGRemove the right crankcase cover(page9-3)

Remove the oil strainer screen and the sealing rubberCheck the screen for damage and the sealing rubber for damage or deterioration.

Reinstall the oil strainer screen and right crankcasecover(page9-17)

ENGINE OIL CENTRIFUGAL FILTERCLEANING

Remove the right crankcase cover, ball retainer and clutchlifter lever(page9-3).

Remove the four screws and clutch outer cover.

Clean the clutch outer cover and inside the clutch outer coverusing a clean lint-free cloth.

CAUTION:Do not allow dust and dirt to enter the crank shaftoil passage.Do not use compressed air.

Reinstall the clutch outer cover using a new gasket(page9-13).

ENGINE IDLE SPEEDWARNINGWhen the engine must be running to do some workmake sure the area is well ventilated.Never run the engine in an enclosed area. The exhaustcontains poisonous carbon monoxide gas that maycause loss of consciousness and lead to death. Runthe engine in an open area or with an exhaust evacuation system in an enclosed area.

NOTE:Inspect and adjust the idle speed after all otherengine maintenance items have been performed andare within specifications.The engine must be warm for accurate idle speed inspection and adjustment.

Warm up the engine for about ten minutes.Connect a tachometer.Turn the throttle stop screw as required to obtain the specified idle speed.

MAINTENANCE

IDLE SPEED:1,700±100 rpm.

STRAINER SCREEN

OUT COVER

GASKET

THROTTLE STROP SCREW

DRIVE CHAINDRIVE CHAIN SLACK INSPECTION

WARNINGNever inspect and adjust the drive chain while the engineis running.

Turn off the engine, place the motorcycle on its side standand shift the transmission into neutral.Check the slack in the lower drive chain midwaybetween the two sprockets.CHAIN SLACK:15-25mm(5/8-1in)

CAUTION:Excessive chain slack,40mm(1-1/2in)or more, may damage the frame.

ADJUSTMENTLoosen the axle nut.Loosen the adjuster lock nuts and turn both adjusting nutsan equal number of turns until the correct drive chain slackis obtained.

Make sure the index marks on both adjusters are alignedwith the index lines on the swingarm.Tighten the rear axle nut to the specified torque.

TORQUE:47N.m(4.8kgf.m,345ibf.ft)

Tighten both lock nuts

Recheck the drive chain slack and free wheel rotation.Check the rear brake pedal free play(page3-15),adjustif necessary.Lubricate the drive chain.Wipe off the excess oil.

CLEANING INSPECTION AND LUBRICATIONIf the drive chain becomes extremely dirty, it should beremoved and cleaned prior to lubricationCarefully remove the retaining clip with pliers.Removed the link plate and then the master link and now the drive chain can be removed from the sprockets.

Clean the chain with non-flammable or high flash pointsolvent and wipe it dry.Be sure the chain has dried completely before lubricating.Lubricate the drive chain with #80-90 gear oil.Wipe off the excess gear oil.

Inspect the drive chain for possible damage or wear.Replace any chain that has damaged rollers, loose fittinglinks, or otherwise appears unserviceable

Measure the drive chain length between a span of 41 pins(40 links) from pin center to pin center with the chain heldtaut and any kinked joint straightened.

SERVICE LIMIT:511mm(20.1in)

Installing a new chain on badly worn sprockets will causethe new chain to wear quickly.Inspect the teeth on both sprockets for wear or damage. Replace if necessaryNever use a new drive chain on worn sprockets.Both chain and sprockets must be in good condition, orthe new replacement parts will wear rapidly.

Check the attaching bolts and nuts onboth sprockets.If any are loose, torque them.

MAINTENANCE

MAINTENANCE

15-25mm(5/8-1in)

NON-FLAMMABLE ORHIGH FLASH POINT SOLVENT

CLEAN

WIPE AND DRY

LUBRICATE CHAIN SPRAY

41 PINS (40 LINKS)

WEAR

DAMAGE NORMAL

Install the drive chain onto the sprockets.Install the master link and link plate.Install the retaining clip so that its open end is oppositethe normal rotation of the chain.

DRIVE CHAIN SLIDER

Check the drive chain slider for wear or damage.

Replace the drive chain slider if the wear limit guide lug is worn out or it has been damaged.

BRAKE SYSTEMFRONT BRAKEMeasure the front brake lever free play at the tip of the lever .FREE PLAY:10-20mm(3/8-13/16IN)

REAR BRAKECheck the brake pedal free play.FREE PLAY:10-20MM(3/8-13/16IN)

Adjust the brake pedal free play by turning the adjustingnut.Make sure the cutout on the adjusting nut seated on thejoint pin.

CLUTCH SYSTEMIf the clutch does not operate properly, adjust by doing the following:Loosen the clutch adjuster lock nut and turn the adjusting boltone full turn counter clockwise.

SIDE STANDSupport the motorcycle on level surface.

Check the side stand spring for damage or loss of tension.Check the side stand assembly for freedom of movementand lubricate the side stand pivot if necessary.

MAINTENANCE

MAINTENANCE

MASTER LINK

LINK PLATE

RETAINING CLIP

DRIVE CHAIN SLIDER

LOCK

ADJUSTING BOLT

SPRING

SIDE STAND

SUSPENSIONWARNINGLoose, worn or damaged suspension parts impairmotorcycle stability and control. Repair or replace anydamaged components before riding .Riding a motorcycle with faulty suspension increases yourrisk of an accident and possible injury.

FRONT SUSPENSION INSPECTIONCheck the action of the fork legs by operating the front brakeand compressing the front suspension several times.Check the entire assembly for signs of leaks ,damage or loosefasteners.Replace damaged components which cannot be repaired.Tighten all nuts and bolts.

Refer to section 12 for fork service.

REAR SUSPENSION INSPECTIONSupport the motorcycle on safety stand or box and raisethe rear wheel off the ground.

Hold the swingarm and move the rear wheel sidewayswith force to see if the wheel bearings are worn.

Check for worn or loose suspension pivot componentsby grabbing the swingarm and attempting to move theswingarm side to side.Check each fastener on the swingarm and shock absorber,if any looseness is noted.

Check the action of the shock absorber by compressing it several times.Check the entire shock absorber assembly for signs of leaks ,damage or loose fasteners.Replace damaged components which cannot be repaired.Tighten all nuts and bolts.

Refer to section 13 for shock absorber and swingarmservice.

WHEELS/TYRESRECOMMENDED TYRE PRESSURE AND TYRE SIZE:

FRONTTyre pressure kPa(kgf/cm2,psi)

Tyre pressure shouldbe checked when the TYRES are COLD.Check the tyres for cuts, embedded nails, or other damage.Check the front and rear wheel for trueness (refer tosection 12 and 13)Measure the tread depth at the center of the tyres.Replace the tyres when the tread depth reaches the followinglimits.MINIMUM TREAD DEPTH:FRONT/REAR:3.0mm(0.12in)

Tighten any loose spokes.

REAR

175(1.75,15) 175(1.75,18)

MAINTENANCE

MAINTENANCE

BRAKE DISC

TOOL:Spoke wrench,4.1*4.5 mm 07701-0020100

STEERING HEAD BEARINGSSupport the motorcycle securely and raise the front wheeloff the ground.Check that the handlebar moves freely from side to side.If the handlebar moves unevenly, binds, or has verticalmovement, inspect the steering head bearing (pages 12-15).Check that the control cables do not interfere with handlebarrotation.

LUBRICATION SYSTEM DIAGRAM

LUBRICATION SYSTEM DIAGRAM……4-0 TROUBLESHOOTING…………….4-1

SERVICE INFORMATION………………4-1 OIL PUMP………………………….4-2

4.LUBRICATION SYSTEM

OIL STRAINER

OIL FILTER ROTOR

OIL THROUGH

OIL PUMP

ROCKER ARM

CAMSHAFT

PISTON

CRANKSHAFT

MAINSHAFT

COUNTERSHAFT

KICKSTARTER

SERVICE INFORMATIONGENERAL WARNINGWhen the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousnessand lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Althoughthis is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your handswith soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN.

The oil pump can be serviced with the engine installed in the frame.The service procedures in this section must be performed with the engine oil drained.If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.After the oil pump has been installed, check that there are no oil leaks.

SPECIFICATIONSITEM SERVICE LIMIT

Engine oil capacity At draining 0.6L(0.6US qt, 0.5lmp qt) ---------------------At disassembly 0.8L(0.8US qt, 0.7lmp qt) ---------------------

Recommended engine oil 4-stroke oil or equivalent motor oil ---------------------APL service classification SF or SGViscosity: SAE 10W-30

Oil pump rotor Tip clearance 0.15(0.006) 0.20(0.008)Body clearance 0.02-0.07(0.001-0.003) 0.12(0.005)Side clearance 0.10-0.15(0.004-0.006) 0.20(0.008)

TORQUE VALUESOil pump mounting screw 8N.m(0.8kgf.m,5.8lbf.ft)Oil pump cover screw 5N.m(0.5kgf.m,3.6lbf.ft)

TROUBLESHOOTINGEngine oil level too low or high oil consumption Oil contaminationNormal oil consumption Oil not changed often enoughExternal oil leak Worn piston ring or incorrect piston ring installationWorn piston ring or incorrect piston ring installation Worn valve guide or stem sealWorn cylinder Clogged oil strainer screenWorn valve guide or stem sealOil pump worn or damaged

OIL PUMP

REMOVAL

Remove the clutch assembly(page9-4)

When the oil pump is ready to be disassembled, loosenthe pump cover screws.Remove the three screws and oil pump assembly.

DISASSEMBLYRemove the three screws and oil pump cover Remove the oil pump shaft, then remove the inner and outer rotors from the oil pump body.

STANDARD

LUBRICATION SYSTEM

INSPECTIONTemporarily install the outer and inner rotors into the oilpump body.Install the oil pump shaft.

Measure the tip clearance between If any portion of the oil

the inner and outer rotors. pump is worn beyond the

specified service limit,

replace the oil pump as

SERVICE LIMIT:0.20mm(0.008in) an assembly.

Measure the pump body clearance between the outerrotor and pump body.SERVICE LIMIT:0.12mm(0.005in)

Measure the side clearance using a straight edge andfeeler gauge.

SERVICE LIMIT:0.20MM(0.008in)

ASSEMBLY

Install the inner and outer rotors into the oil pump body.Install the oil pump shaft aligning the flat surfaces of theshaft and inner rotor.

Fill the oil pump with 0.5-1cm 3of engine oil.

LUBRICATION SYSTEM

SHAFT

ROTORS

OIL PUMP BODY

OUTER ROTOR

INNER ROTOR

OIL PUMP

OIL PUMP

Install the oil pump cover and tighten the screws to thespecified torque.

TORQUE:5N.m(0.5kgf.m,3.6lbf.ft)

INSTALLATION

Install the rotor shaft collar into crankcaseInstall a new gasket onto the oil pump body.

Install the oil pump into the crankcase while aligning the pump shaft groove with the cam chain guide spindle lug

Install and tighten the three screws to the specified torque.

TORQUE:8N.m(0.8kgf.m,5.8ibf.ft)

Install the clutch assembly(page9-12)

SERVICE INFORMATION---------------------5-1 CARBURETOR ASSEMBLY--------------------5-6TROUBLESHOOTIONG-----------------------5-2 CARBURETOR INSTALLATION----------------5-8AIR CLEANER HOUSING---------------------5-3 AIR SCREW ADJUSTMENT---------------------5-10CARBURETOR REMOVAL-------------------5-3 CRANKCASE BREATHER-----------------------5-11CARBURETOR DISASSEMBLY-------------5-5

SERVICE INFORMATIONGENERALWARNINGGasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDRENBending or twisting the control cable will impair smooth operation and could cause the cable to stick or bindresulting in loss of vehicle control.Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is storedcan cause a fire or explosion.Refer to section 2 for fuel tank removal and installation.When disassembling fuel system parts, note the location of the O-ring. Replace them with new ones on reassemblyBefore disassembling the carburetor, place a suitable container under the carburetor drain tube. Loosen the screwand drain the carburetor.After removing the carburetor, wrap the intake port of the engine with a towel or cover it to prevent anyforeign material from dropping into the engine.

NOTE:If the vehicle is to be stored for more than one month, drain the float bowl, Fuel left in the float bowl may cause cloggedjets, resulting in hard starting or poor drivability.

LUBRICATION SYSTEM

5.FUEL SYSTEM

COVER

OIL PUMP

TROUBLESHOOTING

Engine will not start ●Too much fuel getting to the engine Engine stall ,hard to start, rough idling　-Air cleaner clogged ●Fuel line restricted　-Flooded carburetor ●Ignition malfunction

●Intake air leak ●Fuel mixture too lean or too rich

●Fuel contaminated or deteriorated ●Fuel contaminated or deteriorated●No fuel to carburetor ●Idle speed maladjusted -Fuel strainer clogged ●Float level maladjusted -Fuel tube clogged ●Fuel tank breather tube clogged -Float level maladjusted ●Air screw maladjusted -Fuel tank breather tube clogged ●Slow circuit clogged

Lean mixture ●Fuel jets clogged After burn when engine braking is used ●Float valve faulty ●Lean mixture in slow circuit●Float level too low●Fuel line restricted●Carburetor air vent tube clogged Backfiring or misfiring during acceleration ●Intake air leak ●Ignition mixture in slow circuit●Throttle valve faulty ●Fuel mixture too lean

Poor performance and poor fuel economyRich mixture ●Fuel system clogged●Choke lever in CLOSED position ●Ignition system malfunction●Float valve faulty●Float level too high●Air jets clogged●Air cleaner element contaminated●Flooded carburetor

AIR CLEANER HOUSINGREMOVAL AND INSTALLATION

NOTE:Refer to page 3-5 for air cleaner element service

Loosen the connection tube band screw Remove the bolt and the air cleaner housing assembly

Installation is in the reverse order of removal

At installation secure the ground eyelet with the air cleaner housing mounting bolt.

CARBURETOR REMOVAL

△ WARNINGGasoline is extremely flammable and is explosive under certain conditions .KEEP OUT OF REACH OF CHILDREN

THROTTLE VALVE Loosen the carburetor top

Remove the carburetor top and throttle valve from the carburetor.

FUEL SYSTEM

FUEL SYSTEM

TUBES

CARBURETOR TOP

THROTTLE VALVE

Remove the throttle cable from the throttle valve whilecompressing the throttle valve spring

Remove the jet needle retainer and jet needle

Check the throttle valve and jet needle for scratches or wear or damage

CARBURETOR BODYWARNINGGasoline is extremely flammable and is explosiveunder certain conditions. Work in a well ventilatedarea. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can causea fire or explosion.

Loosen the drain screw and drain the fuel from the floatchamber into an approved gasoline container.

Disconnect the fuel tube and air vent tube and drain tube fromthe carburetor body

Loosen the carburetor connecting tube band screw.Remove the carburetor mounting bolts, carburetor andinsulator

CARBURETOR DISASSEMBLYRemove the screws and float chamber

Remove the float pin and float and float valve.Inspect the float for deformation or damage.

Inspect the float valve seat for scores, scratches, cloggingand damage.Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination.Replace the valve if the tip is worn or contaminatedCheck the operation of the float valve.

Remove the following:-Main jet-Needle jet-Throttle stop screw and spring

Turn the air screw in and carefully count the number of turns until it seats lightly. Make a note of this to use as a reference when reinstalling the air screw.Remove the air screw and spring

FUEL SYSTEM

FUEL SYSTEM

SPRING

VALVE

RETAINERJET NEEDLE

INSULATOR

FLOAT CHAMBER

PIN

FLOAT

FLOAT VALVE

FLOAT VALVE

VALVE SEAT

CAUTION:Damage to the air screw seat will occur if the air screw is tightened against the seat.

Inspect each jet for wear or damage and replace if necessary.Clean the jets with cleaning solvent and blow withcompressed air.

CARBURETOR ASSEMBLY

Blow open each air and fuel passage in the carburetorbody with compressed air.

Install the following:-Throttle stop screw and spring-Needle jet-Main jet

CAUTION:Handle all jets with care. They can easily be scoredor scratched.

Install the air screw with the spring and return it to itsoriginal position as noted during removal.Perform the air screw adjustment procedure if a new airscrew is installed(page5-10).

Hang the float valve onto the float arm lip.Install the float and float valve in the carburetor body, theninstall the float pin through the body and float.

FUEL SYSTEM

FUEL SYSTEM

NEEDLE JET

MAIN JET

AIR SCREWTHROTTLE STOP SCREW

SPRINGSPRING

NEEDLE JET

MAIN JETFLOAT

DRAIN SCREW

O-RING

FLOAT CHAMBERO-RING

THROTTLE

JETNEEDLE

CLI

RETAIN

SPRING

SEAL RING

PIN

FLOAT

MAIN JET

NEEDLE JET

THROTTLESTOP SCREW

SPRING

AIRSCREW

FLOAT

PIN FLOAT VALVE

FLOAT LEVEL INSPECTIONNOTE:Set the float level gauge so that it is perpendicular to the float chamber face and in line with the main jet.

With the float valve seated and the float arm just touchingthe valve, measure the float level with the special tool as shown.

FLOAT LEVEL:19mm(0.75in)TOOL:Carburetor float level gauge 07401-001000

The float cannot be adjusted.Replace the float assembly if the float level is out of specification.

Install a new o-ring into the carburetor groove properly.Install the float chamber.

Install and tighten the flat chamber screws.

CARBURETOR INSTALLATIONCARBURETOR BODY

Install new o-ring into the insulator and carburetor bodygrooves.

Install the carburetor body into the air cleaner connectiontube and the insulator between the manifold and carburetor,then install the mounting bolts.Tighten the connecting tube band screw and mountingbolts.

TORQUE:Connecting tube:1N.m(01kgf.m,0.7lbf.t)

THROTTLE VALVEInstall the needle clip on the jet needle STANDARD POSITION:3rd groove from top (CR70) 4th groove from top(CR107)

FUEL SYSTEM

FLOATCHAMBER

O-RING

O-RING

INSULATOR

BOLTS

CLIP

Install the jet needle into the throttle valve and secure itwith the needle clip retainer.

Check the seal ring is in good condition, replace if necessary.Install the throttle valve spring onto the throttle cable.

Connect throttle cable to the throttle valve whilecompressing the throttle valve spring.

Install the throttle valve into the carburetor body, aligningits cut-out with the throttle stop screw.

FUEL SYSTEM

6.ENGINE REMOVAL AND INSTALLATION

THROTTLE VALVEJET NEEDLE

RETAINER

SEAL RING

SPRING

CABLE

THROTTLE

ALIGN

31 N·m (3.2 kgf.m ·m , 23lbf.ft ·ft)

SERVICE INFORMATION------------------------6-1 ENGINE INSTALLATION----------------6-4

ENGINE REMOVAL--------------------------------6-2

SERVICE INFORMATION

GENERALDuring engine removal and installation, support the motorcycle securely using a hoist or equivalent.Support the engine using a jack or other adjustable support for ease of engine hanger bolts removal.The following components can be serviced with the engine installed in the frame.-alternator/cam chain tensioner (section 10)-clutch (section 9)-cylinder/piston(section8)-cylinder head/valves (section 7)-gearshift linkage(section9)-oil pump (section4)The crankshaft, transmission and kickstarter require engine removal for service(section11).

SPECIFICATIONSITEM

Engine dry weight

TORQUE VALUES

Drive sprocket fixing plate bolt 12N.m(1.2kgf.m,9lbf.ft)Engine hanger nut (upper) 31N.m(3.2kgf.m,23lbf.ft) (lower) 31N.m(3.2kgf.m,23lbf.ft)


ENGINE REMOVALDrain the engine oil(page3-9)Remove the following:-exhaust system(page2-5)-left crankcase cover(page10-2)

Disconnect the following:-spark plug cap

-crankcase breather tube

Remove the following from the clamp:-carburetor drain tube

Loosen the rear axle nut and drive chain adjusters to loosen the drive chain (page 3-12)

Remove the following:-fixing plate bolts -fixing plate -drive sprocket

-intake manifold bolts -0-ring

21kg(46.3lbs)SPECIFICATIONS


PLATE

SPROCKET

BOLT

-brake pedal return spring

-four bolts and foot peg barsupport the motorcyclesecurely.

-engine hanger nuts and washers Place the floor jack or other adjustable support under the engine

Remove the hanger bolts and the engine from the frame

CAUTION:During engine assembly removal , hold the engine securely and be careful not to damage the frame andengine.

ENGINE INSTALLATIONInstall the engine into the frame in the reverse order of removal.

NOTE:●Note the installation of the hanger bolts. All bolts areinstalled from left side.●The jack height must be continually adjusted to relievestress from the hanger bolts.

Tighten the hanger nuts to the specified torque

TORQUE:31N-m(3.2kgf-m,23Ibf-ft)

Install the removed parts from engine removal procedure(page 6-2 to 6-3)in the reverse order of removal.

NOTE:●Replace the intake manifold o-ring with a new one.●Note the installation of the brake pedal return spring.

TORQUE:Fixing plate bolt :12N-m(1.2kgf-m,9Ibf-ft)

Install the following:-left crankcase cover (page 10-8)-exhaust system (page 2-5)

Adjust the drive chain slack (page 3-12)Fill with the recommended engine oil (page 3-9)


SERVICE INFORMATION---------------7-1 CAMSHAFT REMOVAL-------------------7-3

TROUBLESHOOTING-------------------7-2 CYLINDER HEAD--------------------------7-4

CYLINDER COMPRESSION-----------7-3 CAMSHAFT INSTALLATION-------------7-15

SERVICE INFORMATIONGENERALThis section covers service of the cylinder head, valves and camshaft.The cylinder head, valves and camshaft services can be done with the engine installed in the frame.When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.Clean all disassembled parts with cleaning solvent and dry them off with compressed air before inspection.Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder head.Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.Refer to section 10 for cam chain tensioner service.SPECIFICATIONS

ITEM

Cylinder compression 981-1,177kpa(10.0-12.0kgf/cm 2,142-17lpsi)at 1,000 rpm

Cylinder head warpageValve, Valve clearance IN 0.05±0.02(0.002±0.001)valve guide EX 0.05±0.02(0.002±0.001)

Valve stem O.D IN 4.970-4.985(0.1957-0.1963)EX 4.955-4.970(0.1951-0.1957)

Valve guide I.D. IN/EX 5.000-5.012(0.1969-0.1973)Stem-to-guide clearance IN 0.015-0.042(0.0006-00017)

EX 0.030-0.057(0.0012-0.0022)Valve seat width IN/EX 1.0-1.3(0.04-0.05)

Valve spring free length

Rocker arm/shaft Rocker arm I.D. IN/EX 10.000-10.015(0.3937-0.3943)Rocker arm shaft O.D. IN/EX 9.978-9.987(0.3928-0.3932)

Camshaft Cam lobe height 90/110cc IN26.563-26.683(1.046-1.051)EX26.326-26.446(1.036-1.041)

125cc IN26.507-26.637(1.044-1.048)EX26.321-26.441(1.036-1.041)

IN/EX(1)32.78IN/EX(D)35.55

STANDARD


7.CYLINDER HEAD/VALVES

12 N·m (1.2 kgf.m , 9 lbf.ft)

11 N·m (1.1 kgf.m , 8 lbf.ft)

11 N·m (1.1 kgf.m , 8 lbf.ft)

TORQUE VALUESCylinder head nut 11N.m(1.1 kgf.m, 8 lbf.ft. ft)Cylinder head right side cover bolt 10N.m(1.0 kgf.m, 7 lbf.ft. ft)Cam sprocket bolt 9N.m(0.9 kgf.m, 6.5lbf.ft)

TOOLSValve spring compressor 07757-001000Valve spring compressor attachment 07959-KM30101Valve guide reamer,5.0mm 07742-MA60000Valve guide reamer,5.0mm 07984-MA60001 or 07984-MA6000C(U.S.A. only)Valve seat cutters --These are commercially available in Seat cutter,24mm (45 .IN) 07780-0010600 Seat cutter,20.5mm(45 .EX) 07780-0011000 Flat cutter ,24mm(32 .IN) 07780-0012500 Flat cutter ,21.5mm(32 .EX) 07780-0012800 Interior cutter.22mm(60 .IN/EX) 07780-0014202

07781-0010400

TROUBLESHOOTING

Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compressiongauge or by tracing engine noises to the top-end with a sounding rod stethoscope.If the performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smokycheck for a seized piston ring (Section 8).

Compression too low, hard starting or poor Excessive noiseperformance at low speed Cylinder head:Valves: -Incorrect valve clearance -Incorrect valve clearance -Sticking valve or broken valve spring -Burned or bent valve -Damaged or worn camshaft -Incorrect valve timing -Loose or worn cam chain -Broken valve spring -Worn or damaged cam chain -Uneven valve seating -Worn or damaged cam chain tensionerCylinder head: -Worn cam sprocket teeth -Leaking or damaged head gasket -Worn rocker arm and/or shaft -Warped or cracked cylinder head Worn cylinder, piston or piston rings (section 8)Worn cylinder, piston or piston rings (section 8)

Rough idleCompression too high, overheating or knocking Low cylinder compressionExcessive carbon build-up on piston crown or on combustion chamber

Excessive smokeCylinder head: -Worn valve stem or valve guide -Damaged stem sealWorn cylinder, piston or piston rings (section 8)

CYLINDER COMPRESSION

Warm up the engine to normal operating temperature.Stop the engine and remove the spark plug (page 3-6)

Install a compression gauge.Shift the transmission into neutral and open the choke lever(OFF).Open the throttle all the way and crank the engine with the kickstarter until the gauge reading stops rising.

COMPRESSION PRESSURE:981-1,177kPa(10.0-12.0kgf/cm 2,142-171psi)at 1,000 rpm.Low compression can be caused by: -Blown cylinder head gasket -Improper valve adjustment -Valve leakage -Worn piston ring or cylinderHigh compression can be caused by: -Carbon deposits in combustion chamber or on piston head



CAMSHAFT REMOVALDrain the engine oil(page3-9)Remove the following: -Valve adjuster hole cap (page 3-7) -Left crankcase cover (page 10-2) -Sealing bolt, tensioner spring and tensioner push rod to loosen the cam chain tensioner (page 10-4)

Disconnect the spark plug cap.Loosen the cylinder head side cover 6 mm bolt.Tap the head of the 6mm bolt and release the cylinder headleft side cover from the cylinder head. Remove the 6 mmbolt ,sealing washer and cylinder head left side cover.

Turn the crankshaft counter clockwise, and align the "O" mark on the cam sprocket with the index notch on the cylinderhead.

Remove the bolts, cam sprocket and dowel pin.Secure the cam chainwith a piece of wire to prevent it from falling into the cylinder.


Loosen the valve adjusting screw fully to make a valveclearance maximum(page3-8).Temporarily install the cam sprocket bolts into the camshaftand remove the camshaft from the cylinder head whileholding the rocker arms.

INSPECTIONTurn the outer race of each camshaft bearing with your finger.The outer race should turn smoothly and quietly.Also check that the bearing inner race fits tightly on the camshaft.Replace the camshaft assembly if the outer race does notturn smoothly and quietly, or if it fits loosely on the camshaft.

Using a micrometer, measure each cam lobe height.

SERVICE LIMITS: 90/110/125cc :IN:26.22mm(1.032in) EX:25.98mm(1.023in)

CYLINDER HEADREMOVALRemove the following: --Muffler (page 2-4) --Camshaft (page 7-3)

Remove the intake manifold bolts.

LEFT SIDE COVER

BOLT ANDWASHER

BOLTS

CAM SPROCKET

ALIGN

DOWEL PIN

CAMSHAFT

Remove the following: -Cap nuts/seating washers -Nut/sealing washer -Cylinder head cover -Gasket

Remove the cylinder head mounting bolt and cylinder head.

Remove the following: -Gasket -Dowel pins -Collar -O-ring

DISASSEMBLYRemove the spark plug.Remove the bolts and cylinder head right side cover.

Temporarily install a 8 mm bolt to the rocker arm shaftand remove the rocker arm shafts and rocker arms.

Remove the valve springs using the special toolsas shown.

TOOLS:Valve spring compressor 07757--0010000.Valve spring compressor attachment 07959--KM30101

CAUTION:To prevent loss of tension ,do not compress the valvesprings more than necessary to remove the cotters.

Remove the following : Mark all parts during -Spring retainer disassembly so they can -Valve spring be placed back in their original -Valve locations. -Stem seal -Valve spring seat -Cotters

INSPECTION

CYLINDER HEADRemove carbon deposits from the combustion chamber.Check the spark plug hole and valve areas for cracks.

Avoid damaging thegasket surface.

Check the cylinder head for warpage with a straight edgeand feeler gauge.SERVICE LIMIT:0.05mm(0.002 in)



NUT AND WASHER

DOWEL PINS

GASKET

O-RINGCOLLAR

RIGHT SIDE COVER

ROCKER ARM

SHAFT

SPRINGSTEM SEAL

SPRING SEAT

VALVE

ROCKER ARMInspect the rocker arm slipper surfaces for wear or damage.Also check that the oil holes are not clogged.

If either rocker arm requiresMeasure the rocker arm I.D. service or replacement, inspect

the cam lobes for scoring,chipping or flat spots.

SERVICE LIMIT: IN/EX>10.10mm(0.398 in)

Inspect the rocker arm shafts for wear or damage.Measure the O.D. of the rocker arm shaft.SERVICE LIMIT:IN/EX:9.91mm(0.390 in)

VALVE SPRINGMeasure the free length of the inner and outer valvesprings.

SERVICE LIMITS:IN/EX:31.8mm(1.25 in)

Replace the springs if they are shorter than the servicelimits.

VALVEInspect each valve for bending, burring or abnormal stemwear.Check valve movement in the guide.Measure and record each valve stem O.D.

SERVICE LIMIT:IN/EX:4.92mm(0.194 in)

Ream the guides to remove any carbon deposits beforemeasuring the guide.Insert the reamer from the combustion chamber side of thehead and always rotate the reamer clockwise.

TOOL:Valve guide reamer,5.0 mm 07984--MA60001 or

07984--MA6000C (U.S.A only)

Measure and record each valve guide I.D.

SERVICE LIMIT:IN/EX"5.03mm (0.198 in)

Subtract each valve stem O.D. from the corresponding guideI.D. to obtain the stem-to-guide clearance.

SERVICE LIMITS: IN:0.08mm (0.003in) EX:0.10mm(0.004in)If the stem-to-guide clearance is out of Reface thespecification, determine if a new guide with valve seatsstandard dimensions would bring the clearance whenever thewithin tolerance. If so, replace any guides as valve guidesnecessary and ream to fit. If the stem-to-guide are replacedclearance is out of specification with a new guide (page7-9)also replace the valve.



VALVE GUIDE REPLACEMENTChill new valve guides in the freezer section of a refrigeratorfor about an hour.Heat the cylinder head to 212-302(100-150.C)with a hot plateor oven.

WARNINGTo avoid burns, wear heavy gloves when handling the heated cylinder head.

CAUTION:Do not use a torch to heat the cylinder head ;it maycause warping.

Support the cylinder head and drive out the valve guides outof the cylinder head from the combustion chamber side.

TOOL:Valve guide driver,5.0mm 07492-MA60000

Coat new O-ring with engine oil and install them ontonew valve guides.While the cylinder is still heated, drive the guides in the cylinder head from the camshaft side until they are fullyseated.

TOOL:Valve guide driver,5.0mm07942-MA60000Let the cylinder head cool to room temperature.

Ream the new valve guide after installation.Insert the reamer from the combustion chamber side ofthe head and always rotate the reamer clockwise.TOOL:Valve guide reamer,5.0mm 07984-MA600001or

07984-MA60000C

NOTE:Use cutting oil on the reamer during this operation.

Clean the cylinder head thoroughly to remove any metalparticles.Reface the valve seat (see below)

VALVE SEAT INSPECTION/REFACING

Clean the intake and exhaust valves thoroughly to removecarbon deposits.Apply a light coating of Prussian Blue to the valve seats.Lap the valves and seats using a rubber the hose or otherhand-lapping tool.

Remove and inspect the valves.CAUTION:The valves cannot be ground. If a valve face is burned or badly worn or if it contacts the seatunevenly, replace the valve.

Inspect the width of each valve seat.STANDARD: 1.0--1.3 mm (0.04--0.05 in)SERVICE LIMIT:2.0mm (0.08in)

If the seat is too wide, too narrow or has low spots, the seat must be ground.


VALVE GUIDE DRIVER

VALVE SEAT REFACING

Valve seat cutters/grinders equivalent valve seat refacing \equipment are recommended to correct worn valve seats.

NOTE:Follow the refacing manufacturers operation instructions.

Use a 45-degree cutter to remove any roughness orirregularities from the seat. Reface the seat with a 45-

degree cutter whenever a valve guide is replaced.

Use a 32-degree (IN:30 )cutter to remove the top 1/4of the existing valve seat material.

Use a 60-degree cutter to remove the bottom 1/4 of theold seat.Remove the cutter and inspect the area you have refaced.

Install a 45-degree finish cutter and cut the seat to theproper width.Make sure that all pitting and irregularities are removed.Refinish if necessary.

Apply a thin coating of Prussian Blue to the valve seat.Press the valve through the valve guide and onto the seatto make a clear pattern.

NOTE:The location of the valve seat in relation to the valve faceis very important for good sealing.

If the contact area is too high on the valve, the seat mustbe lowered using a 32-degree flat cutter.

If the contact area is too low on the valve, the seat mustbe raised using a 60-degree inner vutter.

Refinish the seat to specifications using a 45-degreefinish cutter.



VALVE SEAT CUTTERS

IN：07780-0012500(24 mm/30°）EX：0778-0012800（21.5mm/32°)

IN：07780-0010600(24 mm/30°）EX：0778-0011000（21.5mm/32°)

IN：07780-0014202(22mm）

ROUGHNESS

OLD SEAT WIDTH

CONTACT TOO HIGH

CONTACT TOO LOW

After cutting the seat, apply lapping compound to thevalve face, and lap the valve using light pressure.

Do not allow lappingcompound to enterthe guides.

After lapping ,wash all residual compound off the cylinderhead and valve.

ASSEMBLY

Clean the cylinder head assembly with solvent and blowthrough all oil passages with compressed air.

Install the valve stems with engine oil and insert the valve into the valve guide.To avoid damage to the stem seal, turn the valve slowlywhen inserting.

Install the valve springs with the tightly wound coils facingthe combustion chamber.Install the valve spring retainer.

Install the valve cotters using the special tool as shown.

TOOL:Valve spring compressor 07757-0010000Valve spring compressor attachment 07959-KM30101

CAUTION:Support the cylinder head above the work bench so that the valve heads will not contact anything that cause damage.

Apply engine oil to the rocker arm inner and slippersurfaces.Install the rocker arms and rocker arm shafts.Install the rocker armshaft with is threaded end facing the right side.

Install a new gasket onto the cylinder head right sidecover.Install the right side cover onto the cylinder head.



HAND-LAPPING TOOL

CAMSHAFT

EXHAUST VALVEINTAKE VALVE

CYLINDER HEAD

GASKETRIGHT SIDE COVER

ROCKER ARM SHAFT

ROCKER ARM

VALVECOTTERS

SPRING

VALVESTEM

SPRING SEATVALVE GUIDE

O-RING

RETAINER

SPRING

STEM SEAL

SPRING SEAT VALVE

SIDE COVER

SHAFT

ROCKER ARM

Install the right side cover bolts.

INSTALLATIONClean off the gasket material from the cylinder surface.

Install the following. --New O-ring --Collar --Dowel --New gasket

Route the cam chain through the cylinder head and installthe cylinder head.

Install a new gasket onto the cylinder head and then installthe cylinder head cover.

Install the cylinder head coverwith its arrow mark facing down.

Install the following: -Cap nuts/new sealing washers -Nut/new sealing washer

NOTE:Note the position of the washers and nuts.

Tighten the cylinder head cover nuts to the specifiedtorque.

TORQUE:11N.m(1.1 kgf.m , 8lbf.ft)

Install and tighten the cylinder head mounting bolt.If the cylinder was removed, tighten the cylinder mountingbolt.Install a new O-ring into the groove in the intake manifold.

Install and tighten the intake manifold bolts.Install the following. -Spark plug (page3-7). -Muffler (page 2-4) Camshaft (see below)



HEAD COVERGASKET

ARROW CHAIN

NUT

CAP NUTS

BOLTS

CAMSHAFT INSTALLATIONApply clean engine oil to the camshaft lobes and bearings.Install the camshaft into the cylinder head with its cam lobos facing the combustion chamber while holding therocker arms.

Turn the crankshaft counterclockwise and align the "T" mark with the index notch on the left crankcase.

Install the dowel pin and cam sprocket.

NOTE:Install the cam sprocket with its "O" mark with the indexnotch on the cylinder head.

Install and tighten the cam sprocket bolts to the specifiedtorque.TORQUE:9N.m(0.9kgf.m ,6.5lbf.ft)

Install the cylinder head left side cover onto the cylinderhead with a new gasket.

Set the tab on the side cover against the left side of the stopper on the cylinder head.

Install the 6mm bolt with a new sealing washer into the cylinder head tighten it.

Tighten the two right side cover bolts if the cylinder headwas disassembled.

Install the spark plug cap.

TORQUE:10N.m(1.0kgf.m, 7lbf.ft)

Install the tensioner push rod. spring and sealing bolt(page 10-5).

Adjust the valve clearance (page3-7).Pour the recommended engine (page 3-9)



CAMSHAFT

INDEX NOTCH

"T" MARK

MAR

DOWEL PIN CHAIN

WASHER AND BOLT

SERVICE INFORMATION-----------------8-1 CYLINDER/PISTON INSPRCTION---------8-4

TROUBLESHOOTING---------------------8-2 PISTON INSTALLATION----------------------8-7

CYLINDER REMOVAL---------------------8-3 CYLINDER INSTALLATION------------------8-7

PISTON REMOVAL------------------------ 8-3

SERVICE INFORMATIONGENERAL The cylinder and piston service can be done with the engine installed in the frame. Camshaft lubrication oil is fed to the cylinder head through an orifice in the cylinder head, cylinder and crankcase. sure that orifice is not clogged and that the O-ring and dowel pins are in lace before installing the cylinder.SPECIFICATIONS

ITEM

Cylinder I.D 39.005-39.015(1.5356-1.5360) Out of round Taper Warpage Piston mark direction "IN" mark facing toward the intake side

piston rings Piston O.D. measurement point 8mm(0.3in)from bottom of shirt Piston pin bore I.D. 13.002-13.008(0.5119-0.5121) Piston pin O.D. 12.994-13.000(0.5116-0.5118) Piston-to-piston pin clearance 0.002-0.014(0.0001-0.0006) Piston ring-to-ring Top/Second 0.015-0.050(0.0006-0.0020) groove clearance Piston ring en gap Top 0.05-0.15(0.002-0.0016)

Second 0.05-020(0.002-0.0016)Oil side rail) 0.3-0.9(0.01-0.04)

Cylinder-to-piston clearance 0.010-0.040(0.0004-0.0016)Connecting rod small end I.D 13.016-13.034(0.5124-0.5131)Connecting rod -to-piston pin clearance 0.016-0.040(0.0006-0.0016)

TORQUE VALUESCam chain guide roller in bolt 10N.m(1.0kgf.m, 7lbf.ft)

-------------------------

STANDARD

------------------------- -------------------------

CYLINDER/PISTON

8.CYLINDER/PISTON

10 N·m (1.0kgf·m , 7lbf ·ft)

TROUBLESHOOTING

If the performance is poor at low speeds, check for white smoke in the crankcase breather tube.If the tube is smoky, check for a seized piston ring.

Cylinder compression is too low, or engine is hard to start. Blown cylinder head gasket Worn ,stuck or broken piston ring. Worn or damaged cylinder or piston.

Piston sounds Worn cylinder, piston and/or piston ring.Worn piston pin hole and piston pin. Worn connecting rod small end.

Cylinder compression is too high, or engine overheats or knocks Carbon deposits on the cylinder head and /or piston crown.

Excessive smoke Worn, stuck or broken ring.

CYLINDER REMOVAL

Remove the cylinder head page 7-4)

Remove the cam chain guide roller bolt, washer andguider roller.Remove the mounting bolt and cylinder.

Remove the following: --Rubber packing --Gasket --Dowel pins

PISTON REMOVALRemove the piston in clip with pliers.

Press the piston pin out of the piston and remove the piston.

Do not let the piston pin clipsfall into the crankcase.

Remove the piston rings.Do not damage the pistonrings during removal.

CYLINDER/PISTON INSPECTION

Inspect the cylinder bore for wear or damage.Measure the cylinder I.D. in X and Y axis at three levels.Take the maximum reading to determine the cylinder wear.

SERVICE LIMIT: 39.05mm(1.537in)

Calculate the piston-to-cylinder clearance.Take a maximum reading to determine the clearance.Refer to page 8-5 for measurement of piston O.D.


Calculate the taper and out of round at three levels in Xand Y axis. Take the maximum reading to determine them.SERVICE LIMIT: Taper:0.10mm(0.004in) Out of round:0.10mm(0.004in)

CYLINDER/PISTON

CYLINDER

GASKET

PISTON

CIRCLIP

Y

TOP

MIDDLE

BOTTOM

The cylinder must be rebored and an oversize piston fittedif the service limits are exceeded.

The cylinder must be rebored and an oversize piston fittedif the service limits are exceeded.

The following oversize pistons are available: 0.25mm(0.010in) 0.50mm(0.020in)

The piston to cylinder clearance for the oversize pistonmust be:0.010-0.040mm(0.0004-0.0016in).

Inspect the top of the cylinder for warpage.

SERVICE LIMIT:0.05mm(0.002in)

Remove any carbon deposits from the piston ring grooves,using an old piston ring as shown.

Temporarily install the piston to their proper position withthe mark facing up.

Measure the piston ring-to-ring groove clearance with the rings pushed into the grooves.

SERVICE LIMITS: Top:0.12mm(0.005in)

Second:0.12mm(0.005in)

inspect the piston for wear or damage.

Measure the diameter of the piston at 8mm(0.3in)fromthe bottom and 90 degrees to the piston pin hole.


Measure the piston pin bore.SERVICE LIMIT:13.06mm(0.514in)

Measure the O.D. of the piston pin.


Calculate the piston-to-piston pin clearance.


Measure the connecting rod small end I.D.

SERVICE LIMIT: 13.08MM(0.515in)

Calculate the connecting rod-to-piston pin clearance


Insert the piston rigs squarely into bottom of the cylinderand measure the ring end gap.

CYLINDER/PISTON

CYLINDER/PISTON

SERVICE LIMITS:Top: 0.5mm(0.02in)Second: 0.5mm(0.02in)Oil side rail): 1.1mm(0.04in) Push the ring into the cylinder with the top of the piston to be sure they are squarely in the cylinder.

PISTON RING INSTALLATIONClean the piston ring grooves thoroughly and install thepiston rings.NOTE: Apply oil to the piston rings. Avoid piston and piston ring damage during installation. Install the piston rings with their marking facing up. Do not confuse the top and second rings.

Space the piston ring end gaps 120 degrees apart.Do not align the gaps in the oil rings side rails).

After installation, the rings should rotate freely in the ringgrooves.

PISTON INSTALLATIONApply oil to the piston pin outer surface.Install the piston with its: "IN" mark facing the intake side.Install the piston pin and secure it with new piston pin clips.

NOTE:Do not align the piston pin clips end gap with the pistoncut-out.Do not let the piston pin clips fall into the crankcase.

CYLINDER INSTALLATION

Clean off any gasket materials from the crankcase surface.

Install the dowel pins, new gasket and new rubber packing

Coat the cylinder bore, piston outer surface and pistonring grooves with clean engine oil.Route the cam chain through the cylinder and install thecylinder while compressing the piston rings.

NOTE:Avoid piston ring damage during installation.Do not let the cam chain fall into crankcase.

Apply engine oil to the guide roller inner surface.Install the cam chain guide roller, new sealing washer andpin bolt.Tighten the cam chain guide roller pin bolt go the specifiedtorque.


Install the cylinder mounting bolt but do not tighten it yet.Install the cylinder head (page 7-14).

9.CLUTCH /GEARSHIFT LINKAGE

SERVICE INFORMATION--------------------9-1 CLUTCH--------------------------------------9-4

TROUBLESHOOTING-----------------------9-2 GEARSHIFT LINKAGE--------------------9-14

RIGHT CRANKCASE-------------------------9-3 RIGHT CRANKCASE---------------------9-17COVER REMOVAL COVER INSTALLATION

SERVICE INFORMATIONGENERALThis section covers service of the clutch and gearshift linkage. All service can be done with the engine installedin the frame.Use care not to allow dust or dirt to enter the engine.Transmission oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengageor the motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system.SPECIFICATIONS

ITEM SERVICE LIMITClutch disc thickness A :A:1.52-1.68(0.060-0.066) 1.3(0.051)

3.2(0.126): A:2.67-2.83(0.105-0.114) 2.45(0.096)

3.2(0.126)B 3.0(0.12)

Clutch plate warpage 0.20(0.008)Centrifugal clutch spring free length 19.4(0.76)Primary drive gear 21.05(0.829)Clutch center guide L.D 17.04(0.671)

O.D 20.9(0.823)Crankshaft O.D. at clutch center guide 16.9(0.665)

TORQUE VALUESClutch outer cover screw 5N.m(0.5kgf.m, 3.6lbf.ft)Clutch lock nut 42N.m(4.3kgf.m, 31lbf.ft)Clutch assembly screw 6N.m(0.5kgf.m, 3.6lbf.ft)Shift drum stopper arm bolt 13N.m(1.3kgf.m,9lbf,ft)Shift return spring pin bolt 29N.m(3.0kgf.m,22lbf.ft)Gearshift cam plate bolt 17N.m(1.7kgf.m,12lbf.ft)

TOOLS

Flywheel holder 07725-0040000Lock nut wrench,20*24mm 07716-0020100extension bar 07716-0020500

CLUTCH /GEARSHIFT LINKAGE

TROUBLESHOOTING

Clutch slips when accelerating Hard to shiftIncorrect clutch adjustment Incorrect clutch adjustmentWorn clutch disc Loose stopper plate boltWeak clutch spring Damaged stopper plate boltFaulty clutch weight Damaged stopper plate and pinTransmission oil mixed with molybdenum or graphiteadditive. Transmission jumps out of gear

Worn shift drum stopper armMotorcycle creeps with clutch disengaged Weak or broken shift arm return springIncorrect clutch adjustment Loose stopper plate blotClutch plate warpedFaulty clutch lifter Gearshift pedal will not returnFaulty clutch weight Weak or broken gearshift spindle returnIncorrect engine oil weight Bent gearshift spindle

RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil(page3-9)Remove the foot peg bar page 6-3)

Remove the bolt kickstarter pedal.

Unhook the brake pedal return spring.Loosen the rear brake pedal adjusting nut and lower the brake pedal.

Remove the eight bolts and right crankcase cover.

20.930-20.950(0.8240-0.8248)16.988-17.006(0.6688-0.6695)

16.966-16.984(0.6680-0.6687)

:19.5(0.77):20(0.79)

B:3.42-3.58(0.135-0.141)3.32-3.48(0.131-0.137)

---------------------

STANDARD

21.0000-21.021(0.8268-0.8276)

B:3.42-3.58(0.135-0.141)

RIGHT CRANKCASE COVER

Remover the gasket and dowel pins.

Remove the clutch adjusting nut, washer and o-ringRemove the clutch lifter/adjusting bolt assembly.

Check the kickstarter oil seal for damage, replace ifnecessary.

CLUTCH

REMOVAL

Remove the ball retainer and spring.Remove the clutch lifer lever.

Remove the oil through and spring.Remove the clutch lifter cam plate.

Remove the screws and clutch outer cover and bearing.


NUT, WASHER AND O-RING

CLUTCH LIFTER ADJUSTING BOLT

BALL RETAINER

LIFTER LEVER

SPRING

SPRING LIFTER CAM PLATE

OIL THROUGH

OIL SEAL

Straighten the tab of the lock washer.

Hold the clutch outer with the flywheel holder and removethe lock nut using the special tools as shown.

TOOLS: 07725-0040000Flywheel holder

Lock nut wrench,20x24mm 07716-0020100Extension bar 07716-0020500

Remove the lock washer B,14mm lock washer and clutch assembly.

Remove the primary dive gear.

Remove the clutch center guide.

Remove the snap ring and primary driven gear from the mainshaft.Remove the collar from the crankshaft.

DISASSEMBLY

Remove the following: -Set ring -Clutch plate B -Clutch disc A -Clutch disc B -Clutch disc A -Free springs -Clutch plate A

Remove the clutch center and drive gear outer.



14MM LOCK WASHER

LOCK WASHER

DRIVE GEAR

DRIVE GEAR

SNAP RINGDRIVEN GEAR

SET RING PLATE AND DISCS

CLUTCH CENTER

Remove the four damper springs.Remove the four screws and plain washers.

Remove the drive plate assembly and clutch springs.

Remove the clutch weight stopper ring.Remove the clutch weight/center ring.

INSPECTIONClutch lifter bearingTurn the inner race of the lifter bearing with your finger.The bearing should turn smoothly and freely withoutexcessive play.Also check that bearing fits tightly in the clutch outercover.If necessary replace the bearing.

Clutch springMeasure the clutch spring free length.


Clutch disc Replace the clutch discs if they show signs of scoring ordiscoloration.

Measure the disc thickness of disc.

SERVICE LIMITS: Clutch disc A:2.3mm(0.09 in)

Clutch disc B:3.0mm(0.12 in)



DAMPER SPRINGS

SCREWS AND WASHERS

STOPPER RING

CLUTCH WEIGHT/ CENTER RING

DRIVE PLATE ASSEMBLY

Clutch plateCheck each disc plate for warpage on a surface plateusing a feeler gauge.SERVICE LIMIT:0.20mm(0.008in)

Primary drive gear/clutch center guideCheck the primary drive gear and clutch center guidefor excessive wear or damage.

Measure the I.D. of the primary drive gear.

SERVICE LIMIT:21.05mm (0.829 in)Measure the O.D. and I.D of the clutch center guide.SERVICE LIMITS: I.D.:17.04mm(0.671 in) O.D.:20.90mm(0.823in)

CrankshaftMeasure the crankshaft O.D at clutch center guide.

SERVICE LIMIT:16.90mm(0.665 in)

Drive gear outer/clutch centerCheck the dive gear outer and clutch center for excessive wear or damage.

ASSEMBLY

9-9

Install the clutch weight/center ring onto the drive plateby aligning the ring end with the plate hole.Install the stopper ring by aligning the ring end with the plate groove.



CLUTCH CENTER

DRIVE GEAR OUTER

CLUTCH PLATE B

CLUTCH DISC A

FREE SPRINGDRIVE GEAR OUTER

CLUTCH WEIGHT/ CENTER RINGSTOPPER RING

CLUTCH SPRING

CLUTCH DISC B

CLUTCH PLATE A

CLUTCH CENTER

DRIVECLUTCH OUTER

STOPPER RING



Install the clutch spring onto the clutch outer holes.Install the drive plate assembly into the clutch outer aligning its bosses with the clutch springs.

Install the plain washers and screws.Tighten the screws in a crisscross pattern in 2-3 steps.TORQUE:6 N.m(0.6kgf.m,4.3 lbf.ft)

Install the damper springs as shown.

Install the drive gear outer and clutch center.

Install the following: -Clutch plate A _Free springs

-Clutch disc A -Clutch disc B -Clutch disc A -Clutch plate B

NOTE: Install the clutch disc A with its flat surface facing the clutch disc B. Install the clutch plate with its chamfered side facing the clutch disc A.

Install the clutch set ring with its chamfered side facingthe clutch plate B.



SPRINGS

SCREWS AND WASHERS

SPRINGS

DRIVER GEAR OUTER

CLUTCH CENTER

SPRINGS

SET RING

DISC B

DISC A

INSTALLATION

Install the collar onto the crankshaft.

Install the primary driven gear onto the mainshaft andsecure it with the snap ring.

Apply engine oil to the clutch center guide and install itonto the crankshaft.

Install the primary drive gear.

Install the clutch assembly onto the crankshaft.

Install a new 14mm lock washer by aligning its short tabswith the grooves in the dive plate.

Install the lock washer B with its "OUT SIDE" mark facingout.

Install the lock nut.Hold the clutch outer with the flywheel holder and tightenthe lock nut to the specified torque using the special tools'as shown.


Lock nut wrench,20x24mm 07716-0020100Extension bar

TORQUE:42N.m(4.3kgf.m,31 lbf.ft)

If the lock nut groove does not align with the lock washertab, further tighten the lock nut and align.

Bent up the tab of the 14mm lock washer into the grooveof the lock nut.



SNAPRING COLLAR

DRIVEN GEAR

CLUTCH CENTER GUIDE

DRIVE GEAR

14mm LOCK WASHER

LOCK WASHER B("OUTSIDE")

TAB

Clean the inside of the clutch outer and outer cover (page3-10)Install the bearing and a new gasket onto the clutch outercover.

Install the clutch outer cover and tighten the screws to the specified torque.TORQUE:5N.m(0.5kgf.m,3.6lbf.ft)

Install the clutch lifter cam plateInstall the oil through spring and oil through.

Install the spring ,ball retainer and clutch lifter lever.Install the right crankcase cover(page9-17)

GEARSHIFT LINKAGEREMOVALRemove the clutch and primary driven gear(page9-4)Remove the bolt and gearshift pedal.

Clean the gearshift spindle end

to prevent dirt from entering the

crankcase.


GASKET

OUTER COVER

CAM PLATE SPRING

OIL THROUGH

SPRINGBALL RETAINER

LIFTER LEVER

PEDAL

Remove the bolt ,stopper arm and return spring.

Pull down the gearshift arm ,them pull out the gearshiftspindle from the crankcase.

Remove the bolt and shift cam plate.

Remove the dowel pins and gearshift drum pins.

INSPECTIONCheck the gearshift spindle or bends or other damage.

INSTALLATIONInstall the four gearshift drum pins and two dowel pins.

Install the cam plate and tighten the bolt to the specifiedtorque.TORQUE:17N.m(1.7kgf.m, 12lbf.ft)

Install the gearshift spindle into the crankcase by aligningthe return spring ends with the spring pinwheel pushingdown the gearshift arm and set the gearshift arm to theshift drum pins.




BOLT

SPRING

STOPPER ARM

ARM

GEARSHIFT SPINDLE

BOLT CAM PLATE

DRUM PINS

CAM PLATE

BOLT

ARM

ALIGN

GEARSHIFT SPINDLE

Install the return spring and stopper arm as shown andtighten the bolt to the specified torque.

TORQUe:13N.m(1.3kgf.m, 9lbf.ft)

Install the gearshift pedal so that it is same height as thefoot peg.Install the pinch bolt and tighten it.Install the driven gear and clutch assembly (page9-12).

RIGHT CRANKCASE COVERINSTALLATIONInstall the clutch lifter plate/adjusting bolt into the rightcrankcase cover by aligning is pin with the hole in thecrankcase cover.

Coat a new O-ring with engine oil and install it into thecover groove properly.Install the washer and lock nut.

Install the dowel pins and a new gasket.

Install the right crankcase cover.Install and tighten the eight cover bolts in a crisscrosspattern several steps.

Install the kickstarter as shown and tighten the bolt.Hook the return spring to ten brake pedal and springholding pin as shown.

Install the foot peg bar (page6-4).Adjust the brake pedal free play (page 3-15).

Pour the recommended engine oil (page 3-9).Adjust the clutch (page 3-16).


BOLT

SPRING

STOPPER ARM

PEDAL

NUTWASHER

DOWEL PINGS


PEDAL

RETURN SPRING

20°

SYSTEM DIAGRAM---------------------------14-0 IGNITION COIL------------------------------------------14-6

SERVICE INFORMATION-------------------14-1 IGNITION CONTROL MODULE----------------------14-6

TROUBLESHOOTING-------------------------14-2 ENGINE STOP SWITCH/IGNITION SWITCH---14-7

IGNITION SYSTEM INSPECTION---------14-3 IGNITION TIMING----------------------------------------14-7

SERVICE INFORMATIONGENERALWARNINGWhen the engine must be running to do some work, make sure the area is well-ventilated. Never run the enginein an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousnessand lead to death .Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 14-3.The CDI ignition system uses an electrically controlled ignition timing system. No adjustments can be madeto the ignition timing.The ICM may be damage if dropped. Also if the connector is disconnected when current is flowing, the excessivevoltage may damage the module.A faulty ignition system is often related to poor connections. Check those connections before proceeding/Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.For alternator and ignition pulse generator removal and installation, see section 10.

SPECIFICATIONSITEM

Spark plug Standard U20FSR-U(DENSO)For cold climate/below 41 F/5 C U16FSR-U(DENSO)For extended high speed riding U22FSR-U(DENSO)

Spark plug gapIgnition coil peak voltageIgnition pulse generator peak voltageAlternator exciter coil peak voltageIgnition timing ("F" mark)

TORQUE VALUESIgnition coil mounting bolt 6N.m(0.6 kgf.m,4.3lbf.ft)

TOOLSPeak voltage tester (U.S.A.only ) or 07HGJ-0020100(not available in U.S.A.) with commerciallyPeak voltage adaptor available digital multimeter (impedance 10M/DCV minimum)

27 BTDC at idle

0.60-0.70mm(0.024-0.028in)100 V minimum0.7 V minimum100 V minimum

SPECIFICATIONSCR6HSA(NGK)CR5HSA(NGK)CR7HSA(NGK)

14.IGNITION SYSTEM

TROUBLESHOOTINGInspect the following before diagnosing the system -Faulty spark plug -Loose spark plug cap or spark plug wire connections -Water got into the spark plug cap (leaking the ignition coil secondary voltage)

No spark at spark plugusual conditionIgnition coil Low peak voltage1.Incorrect peak voltage adaptor connections (system is normal if measuredprimary voltage is over the specifications with reverse connections).voltage 2.The multimeter impedance is too low;10MO/DCV.

3.Cranking speed is too low (operating force of the kickstarter is weak).4.The sampling timing of the tester and measured pulse were not synchronized(system is normal if measured voltage is over the standard voltage at leastonce).5.Poorly connected connectors or an open circuit in ignition system6.Faulty exciter coil (Measure peak voltage.)7.Faulty ignition coil.8.Faulty ICM (in case when above no.1-7 are normal).

No peak voltage 1.Incorrect peak voltage adaptor connections (system is normal if measured voltage is over the specifications with reverse connections).2.Short circuit in ignition switch wire or engine stop switch wire (black/white.)3.Faulty ignition switch wire or engine stop switch wire (black/white).4.Loose or poorly connected ICM connectors.5.Open circuit or poor connection in ground wire (green )of the ICM>6.Faulty peak voltage adaptor.7.Faulty exciter coil (measure peak voltage.)8.Faulty ignition pulse generator (measure peak voltage.)9.Faulty ICM (in case when above no.1-8 are normal).

Peak voltage is nor1.faulty spark plug or leaking ignition coil secondary current ampere.but no spark jumps2.faulty ignition coil.

Exciter coil Low peak voltage1.the multimeter impedance is too low;10MO/DCV.2.cranking speed is too slow (operation force of the kickstarter is weak.)3.the sampling timing of the tester and measured pulse were dot synchronized(system is normal if measured voltage is over the standard voltage at leastonce).4.Faulty exciter coil (in case when above no.1-3 are normal).

No peak voltage 1.Faulty peak voltage adaptor.2.Faulty exciter coil.

Ignition Low peak voltage1.The multimeter impedance is too low;10MO/DCV.pulse 2.Cranking speed is too slow (operating force of the kickstarter is weak).Generator 3.The sampling timing of the tester and measured pulse were not synchronized

(system is normal if measured voltage is over the standard voltage at leastonce).4.Faulty ignition pulse generator (in case when above no. 1-3 are normal).1.Faulty peak voltage adaptor.2.Faulty ignition pulse generator.

IGNITION SYSTEM INSPECTIONNOTE:If there is no spark at plug, check all connections forloose or poor contact before measuring each peak voltage.

Probable cause Check in numerical order)

No peak voltage

IGNITION SYSTEM

17 N·m (1.7kgf·m, 12lbf·ft)

13 N·m(1.3kgf·m, 9lbf·ft)

42 N·m(4.3kgf·m, 31lbf·ft)

5 N·m(0.5kgf·m, 3.6lbf·ft)

SERVICE INFORMATION--------------------9-1 CLUTCH--------------------------------------9-4

TROUBLESHOOTING-----------------------9-2 GEARSHIFT LINKAGE--------------------9-14

RIGHT CRANKCASE-------------------------9-3 RIGHT CRANKCASE---------------------9-17COVER REMOVAL COVER INSTALLATION

SERVICE INFORMATIONGENERALThis section covers service of the clutch and gearshift linkage. All service can be done with the engine installedin the frame.Use care not to allow dust or dirt to enter the engine.Transmission oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengageor the motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system.SPECIFICATIONS

Clutch disc thickness A SUPER :A:1.52-1.68(0.060-0.066

JNR: A:2.67-2.83(0.105-0.114)

B

L.D.O.D.

TORQUE VALUESClutch outer cover screw 5N.m(0.5kgf.m, 3.6lbf.ft)Clutch lock nut 42N.m(4.3kgf.m, 31lbf.ft)Clutch assembly screw 6N.m(0.5kgf.m, 3.6lbf.ft)Shift drum stopper arm bolt 13N.m(1.3kgf.m,9lbf,ft)Shift return spring pin bolt 29N.m(3.0kgf.m,22lbf.ft)Gearshift cam plate bolt 17N.m(1.7kgf.m,12lbf.ft)

TOOLS

Flywheel holder 07725-0040000Lock nut wrench,20*24mm 07716-0020100extension bar 07716-0020500

20.930-20.950(0.8240-0.8248) 20.9(0.823)Crankshaft O.D. at clutch center guide 16.966-16.984(0.6680-0.6687) 16.9(0.665)

Primary drive gear 21.0000-21.021(0.8268-0.8276) 21.05(0.829)Clutch center guide 16.988-17.006(0.6688-0.6695) 17.04(0.671)

Clutch plate warpage --------------------- 0.20(0.008)Centrifugal clutch spring free length SUPER :19.5(0.77)/JNR:20(0.79) 19.4(0.76)

B:3.42-3.58(0.135-0.141) 3.2(0.126)3.32-3.48(0.131-0.137) 3.0(0.12)

1.3(0.051)B:3.42-3.58(0.135-0.141) 3.2(0.126)

2.45(0.096)

9.CLUTCH /GEARSHIFT LINKAGE

ITEM STANDARD SERVICE LIMIT

TROUBLESHOOTING

Clutch slips when accelerating Hard to shiftIncorrect clutch adjustment Incorrect clutch adjustmentWorn clutch disc Loose stopper plate boltWeak clutch spring Damaged stopper plate boltFaulty clutch weight Damaged stopper plate and pinTransmission oil mixed with molybdenum or graphiteadditive. Transmission jumps out of gear

Worn shift drum stopper armMotorcycle creeps with clutch disengaged Weak or broken shift arm return springIncorrect clutch adjustment Loose stopper plate blotClutch plate warpedFaulty clutch lifter Gearshift pedal will not returnFaulty clutch weight Weak or broken gearshift spindle returnIncorrect engine oil weight Bent gearshift spindle

RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil(page3-9)Remove the foot peg bar (page 6-3)

Remove the bolt kickstarter pedal.

Unhook the brake pedal return spring.Loosen the rear brake pedal adjusting nut and lowerthe brake pedal.

Remove the eight bolts and right crankcase cover.

Remover the gasket and dowel pins.Remove the clutch adjusting nut, washer and o-ring

Remove the clutch lifter/adjusting bolt assembly.


NUT, WASHER AND O-RING

CLUTCH LIFTER ADJUSTING BOLT

Check the kickstarter oil seal for damage, replace ifnecessary.

CLUTCH

REMOVAL

Remove the ball retainer and spring.Remove the clutch lifer lever.

Remove the oil through and spring.Remove the clutch lifter cam plate.

Remove the screws and clutch outer cover and bearing.


OIL SEAL

BALL RETAINER

LIFTER LEVER

SPRING

SPRING

CLUTCH OUTER COVER

OIL THROUGH

LIFTER CAM PLATE

Straighten the tab of the lock washer.

Hold the clutch outer with the flywheel holder and removethe lock nut using the special tools as shown.


Lock nut wrench,20x24mm 07716-0020100Extension bar 07716-0020500

Remove the lock washer B,14mm lock washer and clutch assembly.

Remove the primary dive gear.

Remove the drive gear.

Remove the snap ring and primary driven gear from the mainshaft.Remove the collar from the crankshaft.


14MM LOCK WASHER

LOCK WASHER B

DRIVE GEAR

DRIVE GEAR

SNAP RING DRIVEN GEAR COLLAR

DISASSEMBLY

Remove the following: -Set ring -Clutch plate B -Clutch disc A -Clutch disc B -Clutch disc A -Free springs -Clutch plate A

Remove the clutch center and drive gear outer.

Remove the four damper springs.Remove the four screws and plain washers.

Remove the drive plate assembly and clutch springs.

Remove the clutch weight stopper ring.Remove the clutch weight/center ring.

SET RING PLATE AND DISCS

CLUTCH CENTER

DRIVE GEAR OUTER

DAMPER SPRINGS

STOPPER RING


DRIVE PLATEASSEMBLY

SCREWS AND WASHERS

CLUTCHSPRINGS

INSPECTIONClutch lifter bearingTurn the inner race of the lifter bearing with your finger.The bearing should turn smoothly and freely withoutexcessive play.Also check that bearing fits tightly in the clutch outercover.If necessary replace the bearing.

Clutch springMeasure the clutch spring free length.


Clutch disc Replace the clutch discs if they show signs of scoring ordiscoloration.

Measure the disc thickness of disc.

SERVICE LIMITS: Clutch disc A:2.3mm(0.09 in)

Clutch disc B:3.0mm(0.12 in)

Clutch plateCheck each disc plate for warpage on a surface plateusing a feeler gauge.SERVICE LIMIT:0.20mm(0.008in)

Primary drive gear/clutch center guideCheck the primary drive gear and clutch center guidefor excessive wear or damage.

Measure the I.D. of the primary drive gear.

SERVICE LIMIT:21.05mm (0.829 in)Measure the O.D. and I.D of the clutch center guide.SERVICE LIMITS: I.D.:17.04mm(0.671 in) O.D.:20.90mm(0.823in)

BEARING

CrankshaftMeasure the crankshaft O.D at clutch center guide.

SERVICE LIMIT:16.90mm(0.665 in)

Drive gear outer/clutch centerCheck the dive gear outer and clutch center for excessive wear or damage.

ASSEMBLY

CLUTCH CENTER

DRIVE GEAR OUTER

CLUTCH PLATE B

CLUTCH DISC A

FREE SPRING

DRIVE GEAR OUTER


STOPPER RING

CLUTCH SPRING

CLUTCH DISC B SET RING

CLUTCH PLATE A

CLUTCH CENTER

DRIVE PLATECLUTCH OUTER

Install the clutch weight/center ring onto the drive plateby aligning the ring end with the plate hole.Install the stopper ring by aligning the ring end with the plate groove.

Install the clutch spring onto the clutch outer holes.Install the drive plate assembly into the clutch outer aligning its bosses with the clutch springs.

Install the plain washers and screws.Tighten the screws in a crisscross pattern in 2-3 steps.TORQUE:6 N.m(0.6kgf.m,4.3 lbf.ft)

Install the damper springs as shown.

STOPPER RING



SPRINGS

SCREWS AND WASHERS

SPRINGS

Install the drive gear outer and clutch center.

Install the following: -Clutch plate A _Free springs

-Clutch disc A -Clutch disc B -Clutch disc A -Clutch plate B

NOTE: Install the clutch disc A with its flat surface facing the clutch disc B. Install the clutch plate B with its chamfered side facing the clutch disc A.

Install the clutch set ring with its chamfered side facingthe clutch plate B.

DRIVER GEAR OUTER

CLUTCH CENTER

PLATE A

SPRINGS

SET RING

DISC A

PLATE BDISC B

INSTALLATION

Install the collar onto the crankshaft.

Install the primary driven gear onto the mainshaft andsecure it with the snap ring.

Apply engine oil to the clutch center guide and install itonto the crankshaft.

Install the primary drive gear.

Install the clutch assembly onto the crankshaft.

Install a new 14mm lock washer by aligning its short tabswith the grooves in the dive plate.

SNAP RING COLLAR

DRIVEN GEAR

CLUTCH CENTER GUIDE

DRIVE GEAR

14mm LOCK WASHER

Install the lock washer B with its "OUT SIDE" mark facingout.

Install the lock nut.Hold the clutch outer with the flywheel holder and tightenthe lock nut to the specified torque using the special tools'as shown.


Lock nut wrench,20x24mm 07716-0020100Extension bar

TORQUE:42N.m(4.3kgf.m,31 lbf.ft)

If the lock nut groove does not align with the lock washertab, further tighten the lock nut and align.

Bent up the tab of the 14mm lock washer into the grooveof the lock nut.

Clean the inside of the clutch outer and outer cover (page3-10)Install the bearing and a new gasket onto the clutch outercover.

LOCK WASHER B("OUTSIDE")

TAB

GASKET

Install the clutch outer cover and tighten the screws to the specified torque.TORQUE:5N.m (0.5kgf.m,3.6lbf.ft)

Install the clutch lifter cam plateInstall the oil through spring and oil through.

Install the spring ,ball retainer and clutch lifter lever.Install the right crankcase cover(page9-17)

GEARSHIFT LINKAGEREMOVALRemove the clutch and primary driven gear(page9-4)Remove the bolt and gearshift pedal.

Clean the gearshift spindle end

to prevent dirt from entering the

crankcase.

OUTER COVER

CAM PLATESPRING

OIL THROUGH

SPRING

BALL RETAINER

LIFTER LEVER

PEDAL

Remove the bolt ,stopper arm and return spring.

Pull down the gearshift arm ,them pull out the gearshiftspindle from the crankcase.

Remove the bolt and shift cam plate.

Remove and gearshift drum pins.

BOLT

SPRING

STOPPER ARM

ARM

GEARSHIFT SPINDLE

BOLT

CAM PLATE

DRUM PINS

INSPECTIONCheck the gearshift spindle or bends or other damage.

INSTALLATIONInstall the four gearshift drum pins

Install the cam plate and tighten the bolt to the specifiedtorque.TORQUE: 17N.m (1.7kgf.m, 12lbf.ft)

Install the gearshift spindle into the crankcase by aligningthe return spring ends with the spring pin while pushingdown the gearshift arm and set the gearshift arm to theshift drum pins.

CAM PLATEBOLT

ARM

ALIGN

GEARSHIFT SPINDLE

Install the return spring and stopper arm as shown andtighten the bolt to the specified torque.

TORQUe:13N.m (1.3kgf.m, 9lbf.ft)

Install the gearshift pedal so that it is same height as thefoot peg.Install the pinch bolt and tighten it.Install the driven gear and clutch assembly (page9-12).

RIGHT CRANKCASE COVERINSTALLATIONInstall the clutch lifter plate/adjusting bolt into the rightcrankcase cover by aligning is pin with the hole in thecrankcase cover.

Coat a new O-ring with engine oil and install it into thecover groove properly.Install the washer and lock nut.

BOLT

SPRING

STOPPER ARM

PEDAL

NUTWASHER

O-RING

Install the dowel pins and a new gasket.

Install the right crankcase cover.Install and tighten the eight cover bolts in a crisscrosspattern several steps.

Install the kickstarter as shown and tighten the bolt.Hook the return spring to ten brake pedal and springholding pin as shown.

Install the foot peg bar (page6-4).Adjust the brake pedal free play (page 3-15).

Pour the recommended engine oil (page 3-9).Adjust the clutch (page 3-16).

DOWEL PINGS


PEDAL

RETURN SPRING

20°

10. ALTERNATOR/CAM CHAIN TENSIONER

SERVICE INFORMATION----------- 10-1 CAM CHAIN TENSIONER------------ 10-4

TROUBLESHOOTING----------------- 10-1 STARTER/FLYWHEEL INSTALLATION--- 10-6

FLYWHEEL/STATOR REMOVAL--- 10-2

SERVICE INFORMATIONGENERALThis section covers service of the flywheel, alternator and cam chain tensioner. All service can done with the engine installed the frame.Refer to section 14 for alternator stator inspection.

SPECIFICATIONS

TORQUE VALUES

Flywheel nut 41N.m(4.2kgf.m, 30lbf.ft)Cam chain tensioner sealing bolt 23N.m(2.3kgf.m, 17lbf.ft)Cam chain tensioner pivot bolt 16N.m(1.6kgf.m, 12lbf.ft)

TOOLSUniversal holder 07725-0030000Flywheel puller 07933-GE0000 Only available in U.S.A or 07933-0010000U.S.A

TROUBLESHOOTINGExcessive engine noise* Worn or damaged chain tensioner* Clogged one-way valve* Weak or damaged cam chain tensioner springLoose cam chain* Weak or damaged cam chain tensioner spring* Improper push rod operation* Clogged one-way valve* Air in cam chain tensioner chamber

STANDARD

11.985-12.000(0.4718-0.4724)

111.7(4.40)

SERVICE LIMIT

11.94(0.470)

100(3.9)

ITEM

Cam chain tensioner Push rod O.D

Spring free length


FLYWHEEL/STATOR REMOVALDisconnect the alternator and ignition pulse generator connectors.

Remove the bolt and gearshift pedal.

Remove the three bolts and left crankcase cover.

Hold the flywheel using the universal holder and remove the flywheel nut.

TOOL:Universal holder 07725-0030000

Remove the washer

PEDAL

CRANKCASE COVER

UNIVERSALHOLDER

CONNECTOR


Remove the flywheel using the special tool.

TOOL:Flywheel puller 07933-GE00000

(Not available in U.S.A.)Flywheel puller 07933-0010000

(U.S.A. only)

Remove the woodruff key.

Remove the bolt and wire clamp.Release the wire grommet from the crankcase groove.

Remove the four mounting bolts and wire clamp, andthe ignition pulse generator and stator as an assembly.


Drain the engine oil (page 3-9)Remove the screws and stator base.

Remove the O-rings.

CAM CHAIN TENSIONERREMOVALRemove the stator base (page 10-2)

Remove the sealing bolt, tensioner spring and push rod.

Remove the pivot bolt, tensioner arm and tensioner roller.

ROLLER

BOLT

TENSIONER ARM

STATOR BASE

O RINGS

SPRINGSEALING BOLTAND WASHER


INSPECTION

Measure the tensioner spring free length.

SERVICE LIMIT: 100mm (3.9in)

Check the push rod for wear or damage.Measure the push rod O.D.SERVICE LIMIT: 11.94 mm(0.470in)

INSTALLATION

Install the cam chain tensioner roller, tensioner arm and pivot bolt.Tighten the pivot bolt to the specified torque.

TORQUE: 16N.m(1.6kgf.m,12lbf.ft)

Check the sealing washer is in good condition, replace ifnecessary.Install the push rod, spring, washer and sealing bolt.Tighten the sealing bolt to the specified torque.

TORQUE: 23N.m(2.3kgf.m,17lbf.ft)PUSH RODSPRING

BOLT ANDWASHER

ROLLER

BOLT

TENSIONER ARM


Remove the crankcase sealing bolt and washer.Fill the push rod with 1-2 cm3 of engine oil through thefiller hole.

Check the sealing washer is in good condition and installthe sealing washer and bolt.Tighten the bolt securely.

STATOR/FLY WHEEL INSTALLATIONCheck the stator base oil seal for damage, replace ifnecessary.Apply engine oil to the lip of the oil seal.

Apply engine oil to new O-rings, install them into thecrankcase grooves and stator base groove.

Install the stator base and tighten the screws securely.

CAUTION:Be careful not to damage the oil seal lips.

STATOR BASE

BOLT AND WASHER

O RINGS


Install the stator and ignition pulse generator with the wireclamp and tighten the bolts securely.

Set the wire grommet into the crankcase groove.Install the wire clamp and tighten the bolt.

Clean any oil from the tapered portion of the crankshaftand flywheel.Install the woodruff key into crankshaft.

Install the flywheel by aligning the key way in the flywheelwith woodruff key on the crankshaft.Install the washer and flywheel nut.


Hold the flywheel using the universal holder and tighten

the nut to the specified torque.

TOOL:

Universal holder 07725-0030000

TORQUE: 41N.m(4.2kgf.m,30lbt.ft)

Install the left crankcase cover and tighten the two bolts.

Install the gearshift pedal so that same height as the

footpeg.

Install the pinch bolt and tighten it.

Connect the ignition pulse generator and alternator

connectors.

GEARSHIFTPEDAL

LEFT CRANKCASE COVER

UNIVERSALHOLDER

CONNECTORS

11. CRANKSHAFT/TRANSMISSION/KICKSTARTER

SERVICE INFORMATIONGENERAL* The crankcase must be separated to service the crankshaft, transmission and kickstarter.* The following parts must be removed before separating the crankcase. - Alternator/cam chain tensioner (Section 10) - Clutch/gearshift linkage (Section 9) - Cylinder head (Section 7) - Cylinder/piston (Section 8) - Engine (Section 6) - Oil pump (Section 4)

SPECIFICATIONS

TORQUE VALUESShift drum bolt 12N.m(1.2kgf-m,9lbf-ft)

34.075-34.100(1.3415-1.3425)

0.6(0.024)0.05(0.002)0.10(0.004)34.14(1.344)

0.010-0.350(0.0004-0.0138)0-0.012(0-0.005)Crankshaft

Shift fork

ITEMSide clearanceRadial clearanceRun outI.D

STANDARDUnit: mm (in)

SERVICE LIMIT

CRANKSHAFT/TRANSMISSION/KICKSTARTER

TOOLSDriver 07749-0010000Attachment, 37*40mm 07746-0010200Pilot,17mm 07746-0040400

TROUBLE SHOOTINGHard to shift* Incorrect clutch adjustment* Bent shift fork* Bent fork claw* Damaged shift drum cam groove* Incorrect transmission oil weight

Transmission jumps out of gear* Worm gear dogs and slots* Bent fork shaft* Broken shift drum stopper

Excessive noise* Worn crankshaft big end bearing* Worn crankshaft journal bearing


CRANKCASE SEPARATIONNOTE:Refer to Service Information (page 11-1) forremoval of necessary parts before separating thecrankcase

Remove the snap ring from the kickstarter spindle.Unhook the return spring and remove the retainerAnd return spring.

Remove the rubber cap.

Remove the shift drum bolt and washer.

Remove the cam chain.

Loosen the seven crankcase bolts in a crisscrossPattern in 2-3 steps and remove them.

CAM CHAIN

BOLT AND WASHER

CAP

SPRINRETAINE

SNAP RING


Place the crankcase with the left side down.

Separate the right and left crankcase halves.

Remove the gasket and dowel pins.

CRANKSHAFT

REMOVAL

Remove the crankshaft from the left crankcase.

If necessary, remove the cam chain guide spindle And

guide sprocket.

SPINDLESPROCKET

CRANKSHAFT

LEFT CRANKCASERIGHT CRANKCASE

GASKET

DOWEL PINS


INSPECTION

Measure the connecting rod big end side clearance witha feeler gauge.

SERVICE LIMIT:0.6 mm(0.024 in)

Measure the connecting rod big end radial clearance atsymmetrical points as shown.SERVICE LIMIT: 0.05mm(0.002in)

Turn the outer race of the crankshaft bearing with Yourfinger.The bearing should turn smoothly and quietly.Also check that the inner race of the bearing fits tightlyon the crankshaft.

Check the timing sprocket for wear or damage.

If you replacing the timing sprocket, aline the centerof the sprocket teeth with the center of woodruff keygroove as shown.

TIMINGSPROCKET


Place the crankshaft on a stand or V-blocks and Measurethe runout using a dial gauge.The measuring locations are shown in the illustration

SERVICE LIMIT: 0.10mm (0.004 in)

INSTALLATIONInstall the guide sprocket and guide spindle.

Pour 1-2cm3 of engine oil into the connecting rod big endbearing.Install the crankshaft into the left crankcase, being carefulnot to interfere the connecting rod with the crankcase.Assemble the crankcase halves (page 11-14)

TRANSMISSIONREMOVALRemove the kickstarter spindle (page 11-12)

Remove the mainshaft, countershaft and shift drum as anassembly.

MAINSHAFTCOUNTERSHAFT

SHIFT DRUM

CRANKSHAFT

SPINDLESPROCKE

HOLDHOLD

30 mm 26 mm


TRANSMISSION DISASSEMBLY

Disassemble the mainshaft, countershaft and shift drum.

TRANSMISSION INSPECTION

Check the gear dogs, dog holes and teeth for abnormalwear or lack of lubrication.Measure the I.D. of each gear

SERVICE LIMITS:M2: 17.10mm(0.673 in)C1: 23.10mm(0.909 in)C3: 20.10mm(0.791 in)

Measure the I.D. and O.D. of C1 gear bushing.

SERVICE LIMIT: O.D:22.93mm(0.903in)I.D:20.08MM(0.791in)

Calculate the CI gear-to-bushing clearance.SERVICE LIMIT: 0.10mm(0.004in)

Check the shifter groove of the shifter gear for excessivewear or damage.

Measure the O.D.of the mainshaft and countershaftSERVICE LIMITS:

At M2 gear: 16.95 mm(0.667 in)At C1 gear: 19.94 mm(0.785 in)

Calculate the M2 gear-to-shaft clearance.SERVICE LIMITS: 0.10 mm(0.004 in)Calculate the C1 gear bushing-to-shaft clearance.SERVICE LIMITS: 0.10 mm(0.004 in)

M2

C1

MAINSHAFT

SHIFT DRUM

COUNTERSHAFT


TRANSMISSION ASSEMBLY

GEARSHIFT DRUM DISASSEMBLY

Remove the guide pin clips.Remove the guide pins, then remove the shift forks.

Inspect the shift drum grooves for wear or damage.Measure the O.D. of the shift drum.SERVICE LIMIT: 33.93mm(1.336 in)

SHIFT FORK

GUIDE PIN

CLIP

Assembly is in the reverse order of disassemblyC3 GEAR(25T)

C2 GEAR(25T)

C1 GEAR(36T)

COUNTERSHAFT

MAINSHAFT(M1:11T)

C2 GEAR(15T)

C3 GEAR(21T)

Gear sliding surface, gearteeth

OIL


Measure the shift fork I.D.SERVICE LIMIT: 34.14mm (1.344 in)

Measure the shift fork claw thickness.SERVICE LIMIT: 4.60mm (0.181 in)

SHIFT DRUM ASSEMBLYWASHER

SHIFT FORK

CLIP

GUIDE PINSHIFT DRUM


Apply engine oil to the shift drum outer surface.Install the shift forks onto the gearshift drum.Install the guide pins and secure them with the clips.

If the washer has been removed. Install a new washerand bend the tab to lock the washer.

TRANSMISSION BEARING REPLACEMENT

Turn the inner race of each bearing with your finger.The bearings should turn smoothly and quietly.Also check that the bearing outer race fits tightly in thecrankcase.Remove and discard the bearing if the race does not turnsmoothly, quietly ,or fits loosely in the crankcase.

Remove the countershaft oil seal.

OIL SEAL

WASHER

FORK

GUIDE PINCLIP


Drive the mainshaft bearing out of the right crankcase.

Drive the countershaft bearing out of the left crankcase.

Drive new bearings into the crankcases using the

special tools as shown:

TOOLS:

Drive 07749--001000

Attachment, 37*40mm 07746--0010200

Pilot,17mm 07746--0040400

Apply engine oil to a new countershaft oil seal lip.

Install the countershaft oil seal.OIL SEAL

DRIVER

ATTACHMENT/PILOT

BEARINGLEFT CRANKCASE: COUNTERSHAFT

MAINSHAFT BEARING

RIGHT CRANKCASE


TRANSMISSION INSTALLATION

Apply clean engine oil to the transmission gears and shiftdrum.Set the right fork into the M3 gear and the left fork intothe C2 gear to assemble the mainshaft,Countershaft and shift drum as shown.

Install the mainshaft, countershaft and shift drum as anassembly into the left crankcase.Rotate the shift drum to check the transmission operation.Install the kickstarter spindle (page 11-14)

KICKSTARTERREMOVALRemove the kickstarter spindle from the right crankcase.

DISASSEMBLYRemove the washer.Remove the snap ring and starter ratchet/spring.

RATCHET

WASHER

SPRINGSNAP RING

KICKSTARTER SPINDLE

MAINSHAFT

R. FORK

L. FORKCOUNTERSHAFT


Remove the snap ring, washer and starter pinion gear.

INSPECTIONCheck the kickstarter spindle for bending.Check the friction spring for fatigue.

Check each part for wear or damage, replace if necessary.

ASSEMBLY

KICKSTARTER SPINDLEAssembly is in the reverse order of disassembly

WASHER

SNAP RING

STARTER RATCHETFRICTION SPRING

SNAP RING

WASHERPINION GEAR

PINION GEAR

WASHER

SNAP RING


INSTALLATIONInstall the kickstarter spindle by aligning its friction springwith the groove in the left crankcase as shown.Assemble the crankcase halves.

CRANKCASE ASSEMBLYClean the crankcase mating surfaces before assembling.

NOTE:Dress the surfaces with an oil stone if necessary to Correctany minor roughness or irregularities.Install the dowel pins and a new gasket onto the leftcrankcase.

Install the right crankcase over the left crankcase.

Make sure that thegasket stays in place

Install the seven bolts with the clamp and tighten themin a crisscross pattern in 2-3 steps.

Apply engine oil to the cam chain and install it.

CAM CHAIN

KICKSTARTER SPINDLE

ALIGN

RIGHT CRANKCASE

GASKET

DOWEL PINS


Install the washer and bolt to the shift drum, then tightenthe bolt to the specified torque.TORQUE: 12N.m(1.2 kgf.m, 9lbf.ft)

Install the rubber cap.

Install the return spring and retainer onto the kickstarterspindle.Temporarily install the kickstarter pedal.Install the spring ends onto the retainer and crankcaselug as shown and press the retainer to set its edge againstthe stepped part of the crankcase while turning the pedalcounterclockwise.

Install the snap ring into the groove in the kickstarterspindle securely.

PEDAL

CAP

SPRING

RETAINER

BOLT AND WASHER

SNAP RING

12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING

SERVICE INFORMATIONGENERAL

A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and a contaminateddrum with a high quality brake degreasing agent.

* When servicing the front wheel, brake, fork or steering stem, support the motorcycle using a safety stand or ho

SPECIFICATIONS Unit:mm(in)

100kpa(1.0kgf/cm2,15psi) --------------------Axle runout -------------------------------Wheel rim-to-hub distance --------------------

Radial -------------------------------Axial -------------------------------Brake lever free play --------------------Brake plateSpring free length

TORQUE VALUESHandlebar mounting nut 20N.m(2.0kgf.m, 14ibf.ft)Engine stop switch holder screw 3N.m(0.3kgf.m, 2.2lbf.ft)Brake lever pivot nut 3N.m(0.3kgf.m, 2.2lbf.ft)Brake lever pivot nut 3N.m(0.3kgf.m, 2.2lbf.ft)Spoke nipple 2N.m(0.2kgf.m, 1.4lbf.ft)Front axle nut 47N.m(4.8kgf.m, 35ibf.ft)Front brake arm pinch bolt 6N.m(0.6kgf.m, 4.3lbf.ft)Steering stem nut 74N.m(7.5kgf.m, 54lbf.ft)Steering stem top thread See Page 12-17

376(14.8) 373.5(14.7)Fork

Brake 10-20mm(3/8-13/16in)4 3

Cold tire pressure0.20(0.008)

6.3±1.0(0.25±0.04)

Wheel rim runout 2.0(0.08)2.0(0.08)

Minimum tire tread depth ------------------------------ 3.0(0.12)STANDARD SERVICE LIMITITEM


TOOLSSpoke wrench,4.1*4.5Mm 07707-0020100Bearing remover shaft 07746-0050100Bearing remover head,12mm 07746-0050300Driver 07749-0010000Attachment, 32*35mm 07746-0010100Pilot,12mm 07746-0040200Pin spanner 07702-0020001Ball race remover 07944-1150001Attachment, 37*40mm 07746-0010200Steering stem driver 07946-gc40000 or Steering stem driver 07946-MB00000 with

Steering stem driver attachment07946-GC4000a(U.S.A. only)

TROUBLESHOOTING

Hard steering Wheel turns hard* Faulty or damaged steering head bearings. * Faulty wheel bearing* Insufficient tire pressure * Bent front axle* Steering stem top thread too tight * Brake drag

Steers to one side or does not track straight Soft suspension* Bent fork * Weak fork springs* Bent axle * Tire pressure too low* Wheel installed incorrectly* Faulty steering head bearings Hard suspension* Bent frame * Bent fork tubes* Worn wheel bearing* Worn swingarm pivot components Front suspension noisy

* Damaged or bent fork tubes* Loose fork fasteners

Front wheel wobbling* Bent rim Improper brake performance* Worn front wheel bearings * Incorrect adjustment of lever* Faulty tire * Contaminated brake shoes* Unbalanced tire and wheel * Worn brake shoes

* Worn brake cam* Worn brake drum* Improperly engaged brake arm serrations


HANDLEBAR

REMOVAL

Remove the fuel tank breather tube from the number plateand the number plate from the steering stem nut.

Remove the wire bands.

Remove the two screws and engine stop switch/throttlehousing from the handlebar.

Disconnect the throttle cable and remove the throttle grip.

Remove the left handlebar grip. GRIP

GRIP

CABLE

TUBE

BANDS

NUMBERPLATE


Remove the two nuts and handlebar.INSTALLATION

Install the handlebar into the fork top bridge and tightenthe mounting nuts.TORQUE: 20N.m(2.0kgf.m,14lbf.ft)

Clean the inside surface of the left handlebar grip and theoutside surface of left handlebar.Apply Manufacture Bond a or equivalent to the insidesurface of the left handlebar grip and to the outside surfaceof the left handlebar. Wait 3-5 minutes and install the grip.

Rotate the grip for even application of the adhesive.

NOTE:Allow the adhesive to dry for an hour before using.

Apply grease to the throttle grip pipe flange and installthe throttle grip onto the right handlebar.Connect the throttle cable to the throttle grip pipe flange.

Install the engine stop switch/throttle housing onto thehandlebar, aligning the mating surface with the punchmark on the handlebar.Tighten the forward screw first, then the rear screw.TORQUE: 3N.m(0.3kgf.m,2.2lbf.ft)

GRIP

CABLE

GRIP

NUTS


Secure the engine stop switch wire with the wire baresproperly.

Install the number plate over the steering stem nut andinsert the breather tube into the hoe in the number plate.

Check the throttle grip operation and free play(page 3-4)

FRONT WHEELREMOVAL

A contaminated brake drum or shoe reduces stoppingpower. Discard contaminated shoes and clean acontaminated drum with a high quality brakedegreasing agent…

Support the motorcycle securely using safety stand ora hoist.Remove the axle nut, axle and front wheel.

Remove the side collar from the wheel hub.

WARNING

BRAKE CABLE

NUT AND AXLE

FORK PROTECTOR

TUBE


INSPECTION

AxleSet the axle in v-blocks and measure the runout.Actual runout is 1/2 the total indicator reading.SERVICE LIMIT: 0.20mm(0.008in)

Wheel bearingTurn the inner race of each bearing with your finger.The bearing should turn smoothly and quietly.Also check that the bearing outer race fits tightly in thehub.Remove and discard the bearings if they do not turnsmoothly, quietly, or if they fit loosely in the hub.

Wheel rim runoutCheck the rim runout by placing the wheel in a turning stand.Spin the wheel by hand, and read the runout using a dial indicator.Actual runout is 1/2 the total indicator reading.

SERVICE LIMITS:Radial: 2.0mm(0.08in)Axial: 2.0mm(0.08in)

DISASSEMBLYRemove the dust seal.


Install the bearing remover head into the bearing.From the opposite side, install the bearing remove shaftand drive the bearing out of the wheel hub.Remove the distance collar and drive out the other bearing.

TOOLS:Bearing remover head, 12mm 07746-0050300

(equivalent commerciallyavailable in U.S.A.)

Bearing remover shaft 07746-0050100(equivalent commerciallyavailable in U.S.A.)

ASSEMBLY

CAUTION:Never install the old bearing once the bearings havebeen removed, the bearings must be replaced withnew ones.

Pack each wheel bearing cavities with grease.Drive each wheel bearing cavities with grease.Drive in a new left bearing squarely with its sealed sidefacing out.Install the distance collar and drive in a new right bearingusing the same tools.

TOOLS:Driver 07749-0010000Attachment,32*35mm 07746-0010100Pilot,12mm 07746-0040200

REMOVER HEAD

DISTANCE COLLAR

LEFT WHEEL BEARING

RIGHT WHEEL BEARING

DUST SEAL

DRIVER


Wheel center adjustmentPlace the rim on the work bench.Place the hub with the right side down and begin lacingwith new spokes.Adjust the hub position so that the distance from the hubleft end surface to the side of rim is 6.3±1mm(0.25±0.04in) as shown.

TOOLSpoke wrench, 4.1*4.5mm 07701-0020100

(Equivalent commerciallyavailable in U.S.A.)

TORQUE: 2N.m(0.2kgf,1.4lbf.ft)

Check the rim runout (page 12-8)

Apply grease to a new dust seal lips, then install it into the right wheel hub.

Install the side collar into the right wheel hub.

COLLAR

6.3± 1 mm


Install the front wheel between the fork legs.

Apply a thin layer of grease to the front axle surface.Install the front axle from the right side.Hold the axle and temporarily tighten the axle nut.

With the front brake applied, pump the fork up and downseveral times to seat the axle and check brake operation.

Tighten the axle nut to the specified torque.

TORQUE: 47N.m(4.8kgf.m, 35lbf.ft)

AXLE

AXLE NUT


FRONT BRAKE

ASSEMBLY

1. FR. Wheel Rim Comp2. Flap. FR. Wheel3. Inner Tire 2.50-104. Outer Tire 2.50-105. Bearing6. Distance Collar7. Bush A8. Bush B9. FR. Wheel Axle10. Grip Nut M1211. Bolt12. FR. Brake Disk13. FRONT WHEEL ASSY14. Spoke

Apply grease to the brake cam spindle.Install the brake cam into the brake panel.

NOTICE: need check the brake liquid every timeswhen you drive it.

1. Master Cylinder Body2. Oil Pipe3. Brake Clamp Assembly4. Friction Pad5. FR. Brake lever6. FRONT BRAKE SWITCH7. Holder, Master Cylinder8. Lid, Master Cylinder9. Gasket10. Fixing Bolt11. Bolt M6*2512. Nut M613. SCREW14. Screw15. FRONT BRAKE ASSY

10 14

11

7

1

2

34

13 6

125

98

15

10

11

12

5

8

4

321

657

9

13


NOTICE: need check the Friction Pad when you drive it

1. FR. L. Shock Absorber2. FR. R. Shock Absorber3. Bolt4. Holder, FR. Pipe5. RR. Shock Absorber6. Rubber Cap7. Flange Bolt M6*128. Flange Bolt M8*259. REAR SHOCK ABSORBER10. R.FRONT SHOCK ASSY11. L.FRONT SHOCK ASSY

INSTALLATION

Install the front wheel (page12-8)

FORKDISASSEMBLY

Remove the front wheel (page 12-5)

Loosen the brake cylinder bolt and remove the brakecylinder from the fork stem.

Remove front wheel axle from the fork.Remove the front wheel.

Remove the fork top bolt and washer and pull the forkslider down to remove the fork assembly.

1

3

3

2

74

8

5

6

910

1


Drive out the bolt.

Remove the following from the fork slider-spring-others parts

1. FR.L. Shock Absorber2. FR.R. Shock Absorber3. Bolt4. Holder, FR. Brake Pipe5. RR. Shock Absorber6. Rubber Cap7. Flange Bolt M6*128. Flange Bolt M8*259. REAR SHOCK ABSORBER10. R.FRONT SHOCK ASSY11. L.FRONT SHOCK ASSY

INSPECTIONVisually inspect each part for excessive wear or damage

Measure the fork spring free length

ASSEMBLY

1

3

3

2

74

8

5

6

91

1


Install the following onto the fork slider- new dust seal ( apply grease to the lips)- stopper ring (with the chamfered side facing up)- back up ring- slider guide ( apply 5-6g of grease to the slider guide)sliding surface of the fork slider)

1.FR. L. Shock Absorber2.FR.R. Shock Absorber3.Bolt4.Holder, FR. Brake Pipe5.RR.Shock Absorber6.Rubber Cap7.Flange Bolt M6*128.Flange Bolt M8*259.REAR SHOCK ABSORBER10.R.FRONT SHOCK ASSY11.L.FRONT SHOCK ASSY

Install the slider piston and fork spring/holder asshown.Align the pin holes in the piston, fork slider and springholder so that the locating pin on the upper springholder is facing inside of the fork slider and drive thespring pin to secure them, using a 4mm pin driver.

Be sure that the spring pin do not project out of thepiston outer surface

Apply 5-6g of grease to the slider guide outer groove.Pack the fork spring with 14g of grease.Install the fork assembly by aligning the locating pinwith the groove in the outer tube.

Install the fork top bolt and washer and tighten it.Wipe any excess grease of the outer tube.

15

14 15 16

2

6

4

177

89

111

131210

1.Steering Column Comp2.Upper Panel3.Lower Holder, Handle Pipe4.Upper Holder, Handle Pipe5.Front Cover6.Nut7.Adjusting Nut8.Dust Cap9.Upper Cone Race10.Ball11.Ball Race

12.Bottom Cone Race13.Dust Seal14.Flange Bolt M6×1215.Flange Bolt M8×2516.Flange Bolt M8×2517.Bolt M8×30

1

3

3

2

74

8

5

6

91

1


Install the stopper ring into the groove in the outer tubeproperlyInstall the dust seal over the outer tubeWipe any excess grease of the fork slider.Install the brake cable onto the fork slider and secureit by tightening the cable nut.Install the front wheel (page 12-10)

1. Steering Column Comp 12.Bottom Cone Race2. Upper Panel 13.Dust Seal3. Lower Holder, Handle Pipe 14.Flange Bolt M6*124. Upper Holder, Handle Pipe 15.Flange Bolt M8*255. Front Cover 16.Flange Bolt M8*256. Nut 17.Bolt M8*307. Adjusting Nut8. Dust Cap9. Upper Cone Race10.Ball11.Ball Race

STEERING STEMREMOVAL

Remove the following:- Number plate (page2-3)- handlebar (page 12-3)- Front wheel (page 12-5)- Front fender (page 2-3)- Steering stem nut and washer- Fork top bolts and washers- Top bridge

Remove the steering stem top thread using the specialtool.

TOOL:Pin spanner 07702-0020001

Remove the following- Upper bearing inner race- Upper bearing- Steering stem- Lower bearing

15

14 15 16

2

6

4

177

89

111

131210


BEARING REPLACEMENT Drive out the upper and lower bearing outer races using the special tool.

TOOL: Ball race remove07944- 1150001

Always replace the bearing and races as a set .

Drive new upper and lower bearing outer races into the steering head pipe using the special tools as shown.

TOOLS: Driver 07749-0010000 Attachment ,37×07746-0010200

Temporarily install the steering stem nut onto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem.

Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the stem .

Remove the dust seal and washer.

INSTALLATION

Apply grease to upper and lower bearings and races. Install the lower bearing onto the lower bearing race. Insert the steering stem into the steering head pipe.

Install upper bearing, inner race and top thread.

Hold the steering stem and tighten the stem top thread to the initial torque.

TORQUE:25 N.m(2.5 kgf.m,18 lbf.ft)

move the steering stem right and left, lock-to -lock several rimes to seat the bearings. Loosen the top thread. Retighten the top thread to the specified torque.

TOP THREAD

UPPER INNER

UPPER

UPPER OUTERRACE

LOWER OUTER

LOWER

LOWER INNERDUST SEAL

WASHER

1.Steering Column Comp2.Upper Panel3.Lower Holder, Handle Pipe4.Upper Holder, Handle Pipe5.Front Cover6.Nut7.Adjusting Nut8.Dust Cap9.Upper Cone Race10.Ball11 Ball Race


15

14 15 16

2

6

4

177

89

1011

131210


Install the top bridge. Install the stem nut and fork top bolts with the washers and tighten them TORQUE: stem nut:74 N.m 7.5 kgf.m, 54 lbf.ft)

Make sure that the steering stem moves smoothly without play or binding.

Install the following: --Front fender --Front wheel --Handlebar --Number plate

SERVICE INFORMATION GENERAL △WARNING

·When servicing the rear wheel ,support the motorcycle using a safety stand or hoist. SPECIFICATIONS

ITEM Minimum tire tread depth ——————— Cold tire pressure —————————

Axle run out 0.20(0.008)

Wheel rim run ouRadial ——————— 2.0(0.08)Axial ——————— 2.0(0.08)

Drive chain Size/link DID420MBK1/88 —————————Slack 15-25（9/16-1）

Brake Brake pedal free play 10-20（3/8-13-16） —————————

TORQUE VALUES Spoke nipple 2N.m(0.2kgf.m,1.4lbf. Rear axle nut 47N.m(4.8kgf.m,35lbf.ft) U-nut Driven sprocket nut 32N.m(3.3kgf.m,24lbf.ft) U-nut

Swingarm pivot nut 39N.m(4.0kgf.m,29lbf.ft) Apply grease to the seating surface/U-nut Shock absorber mounting nut 34N.m(3.5kgf.m,25lbf.ft) U-nut Drive chain slider nut 12N.m(1.2kgf.m,9lbf.ft) U-nut

TOOLS Spoke wrench,4.1×4.5mm 07701-0020100 Equivalent commercially available in U.S.A. Bearing remover shaft 07746-0050100 Equivalent commercially available in U.S.A. Bearing remover head,12mm 07746-0050300 Drive 07749-0010000 Spanner,32×35mm 07746-0010100 Pilot.12mm 07746-0040200

TROUBLESHOOTING Soft suspension Rear wheel wobbling·Weak shock absorber spring ·Bent rim·Oil leakage from sampler unit ·Worn rear wheel bearings·Tire pressure too low ·Faulty tire

·Unbalanced tire and wheel Hard suspension ·Tire pressure too low·Bent damper rod ·Faulty swingarm pivot bushings·Damaged swingarm pivot bushings·Bent swingarm pivot·Tire pressure too high

Steers to one side or does not track straight·Bent rear axle·Axle alignment/chain adjustment not equal on both sides

REAR WHEEL

REMOVAL Support the motorcycle securely using a hoist or equivalent and raise the rear wheel off the ground

STANDARD

125kpa(1.25kgf/cm2

,18psi)

—————　

REAR WHEEL/BRAKE/SUSPENSION

SERVICE LIMIT3.0(0.12)

1.Steering Column Comp2.Upper Panel3.Lower Holder, Handle Pipe4.Upper Holder, Handle Pipe5.Front Cover6.Nut7.Adjusting Nut8.Dust Cap9.Upper Cone Race10.Ball11.Ball Race


Loosen the drive chain adjuster lock nuts and adjusting nuts Remove the axle nut and drive chain adjuster

Push the rear wheel forward and derail the drive chain from the driven sprocket

Remove the axle from the left side and remove the rear wheel.

Remove the left side collar the left wheel hub.

INSPECTION Axle Place the axle in V-blocks and measure the run out Actual run out is 1/2 the total indicator reading

SERVICE LIMI0.20mm(0.008 in)

Wheel bearingTurn the inner race of each bearing with your finger Bearings should turn smoothly and quietly .Also checkthat the bearing outer race first tightly in the hub.

Remove and discard the bearings if the races do not turnsmoothly and quietly, or if they fit loosely in the hub.replace the wheel bearings in pairs.Wheel rim run outCheck the rim run out by placing the wheel in a turningstandSpin the wheel slowly and read the run out using a dialindicator.Actual run out is 1/2 the total indicator reading

SERVICE LIMITS:Radial:2.0 mm(0.08in) Axial:2.0 mm(0.08in)

Driven sprocketCheck the condition of the final driven sprocket teeth.Replace the sprocket if worn or damaged

NOTE:·If the final driven sprocket requires replacement inspect the drive chain and drive sprocket·Never install a new drive chain on a worn sprocket or a worn chain on new sprockets. Both chain and sprocket must be in good conditionor the replacement chain or sprocket will wear rapidly

DISASSEMBLYRemove the nuts .bolts and driven sprocketRemove the left dust seal.

Wheel bearing removalInstall the bearing remover head into the bearing From the opposite side install the bearing remover shaftand drive the bearing out of the wheel hub.Remove the distance collar and drive out the other bearing

TOOLS:Bearing remover head ,12mm

07746-0050300(Equivalent

Bearing remover shaft 07746-0050100(Equivalent

ASSEMBLYDISTANCE COLLAR

SIDE

ADJUSTER

AXLE AND NUTCHAIN

REMOVER

DRIVEN SPROCKET

Wheel bearing installation

CAUTION:Never install the old bearings ,once the bearings hasbeen removed, the bearing must be replaced with newones.

Pack each wheel bearing cavity with grease Drive in a new right bearing squarely with the sealed sidefacing up using the special tools as shown.

TOOLS:Driver 07749-0010000

Attachment ,32×35mm 07746-0010100

Pilot ,12mm 07746-0040200

Install the distance collar and drive in a new left bearingusing the same tools.Wheel center adjustmentPlace the rim on the word benchPlace the hub with the left side down and begin lacingwith new spokes.Adjust the hub position so that distance from the hubright end surface to the side of rim is 25±1mm(1.0±0.04in )as shown

TOOL:Spoke wrench ,4.107701-0020100 (equivalent


Check the rim run out (page 13-4)

Apply grease to new dust seal and install it into the left wheel hubInstall the driven sprocket ,bolts and nuts and tighten them


INSTALLATIONInstall the left side collar into the left wheel hub.

Place the rear wheel into the swingarm.

Install the drive chain over the driven sprocket Apply thin layer of grease to the axle Install the axle with the right drive chain adjuster from the right sideInstall the left drive chain adjuster and axle nut.

CHAINAXLE AND

CHAINA S

SIDE

SPROCKET

DRIVE

DRIVE

BEARINGDISTANCE COLLAR

NUTS

BEARING

DUST SEAL

BOLT

DRIVENSPROCKET

25 ± 1

SHOCK ABSORBERREMOVALSupport the motorcycle securely using a hoist or equivalentand raise the rear wheel off the ground .Remove the seat (page 2-2)Remove the shock absorber lower mounting nut and bolt

Remove the upper mounting nut and bolt and the shock absorberINSPECTIONVisually inspect the following :-Spring for fatigue or damage-Damper rod for bend or damage -Damper unit for deformation or oil leaks -Bump rubber for wear or damage-Mounting bushings for damageReplace the shock absorber assembly if necessaryINSTALLATIONInstall the shock absorber into the frame and swingarm

Install the upper and lower mounting bolts from the leftside install the nuts and tighten them to the specifiedtorque


SWINGARMREMOVAL

Remove the following Rear wheel (page 13-3)Drive chain (page 3-12)

Remove the bolts and drive chain coverRemove the bolts .nuts and drive chain guard

Remove the shock absorber lower mounting nut and boltRemove the swingarm pivot nut ,bolt and swingarm .Remove the nut and bolt and the drive chain slider.

INSPECTION

Inspect the swingarm for wear or damage.Inspect the pivot bushings for wear or damage.

INSTALLATION

Install the drive chain slider and tighten the nut.


Install the swingarm over the frame .then install the pivotbolt from the right side and the shock absorber lower mounting bolt from the left side

Apply grease to the seating surface of the swingarmpivot nutInstall an tighten the nuts to the specified torque

REAR SUSPENSION

SLIDER

BUSHIN

CHAIN

CHAIN

BOLT AND NUTBOLT AND NUT

SHOCK

BOLT AND NUT

SHOCK

SWINGARM

TORQUE:swingarm:39N.m(4.0kgf.m,29lbf.ft) Shock absorber:34N.m(3.5kgf.m,25lbf.ft)

BRAKE PEDALREMOVALRemove the rear brake adjusting nut.

Remove the cotter pin ,joint pin.Unhook the brake pedal return spring from the spring holding pin.

Remove the cotter pin ,washer and brake pedal.

INSTALLATION

Apply grease to the pivot groove and install the brake pedal.

Install the washer and a new cotter pin to secure the brakepedal.Install the return spring as shown.Install the spring onto the brake rod the joint pin into the brake arm Install the rod to the brake arm with the adjusting nut.

Connect the brake rod to the pedal with the joint pin and secure it with a new cotter pin .Adjust the brake pedal free play (page 3-15).

14.IGNITION SYSTEMSERVICE INFORMATIONGENERAL△WARNINGWhen the engine must be running to do some work, make sure the area is well -ventilated. Never run the enginein an enclosed area .The exhaust contains poisonous carbon monoxide gas that may cause low of consciousnessand lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

·When servicing the ignition system ,always follow the steps in the troubleshooting sequence on page 14-3.The CDI ignition system uses an electrically controlled ignition timing system .No adjustments can be made to the ignitiontiming·The CDI may be damage if dropped. Also if the connector is disconnected when current is flowing ,the excessivevoltage may damage the module.A faulty ignition system is often related to poor connections. Check those connections before proceeding .Use spark plug of the correct heat range .Using spark plug with an incorrect heat range can damage the engine .For alternator and ignition pulse generator removal and installation ,see section 10.SPECIFICATIONS

SPECIFICATIONS Spark plug Standard CR6HSA (NGK) U20FSR-U (DENSO)

For cold climate/below 410 F/50 C CR5HSA (NGK) U16FSR-U (DENSO)For extended high speed riding SR7HSA (NGK) U22FSR-U (DENSO)

Spark plug gap 0.60-0.70mm (0.024-0.028 in)lgnition coil peak voltage 100 V minimumlgnition pulse generator peak voltage 0.7 V minimumAlternator exciter coil peak voltage 100 V minimum

lgnition timing ("F"mark) 270

BTDC atidle

TORQUE VALUESlgnition coil mounting bolt 6N.m (0.6 kgf.m , 4.3lbf.ft)

TOOLS Peak voltage tester ( U.S.A. only ) or 07HGJ-0020100 (not available in)Peak voltage adaptor available digital multimeter (impede)

TROUBLESHOOTINGInspect the following before diagnosing the system.-Faulty spark plug-Loose spark plug cap or spark plug wire connections-Water got into the spark plug cap (leaking the ignition coil secondary voltage )

ITEM

SPRING

BRAKE

COTTER PIN

WASHER

SPRING

No spark at spark plug Probable cause (Check in numerical order )

1. lncorrect peak voltage adaptor connections (system is normal if measured lgnition coil Low peak voltage voltage is over the specifications with reverse connections ). primary 2. The multimeter impedance is too low ; 10M /DCV. voltage 3. Cranking speed is too low (operating force of the kickstarter is weak ).

4. The sampling timing of the tester and measured pulse were not synchronized (system is normal if measured voltage is over the standard voltage at least once). 5. Poorly connected connectors or an open circuit in ignition system . 6. Faulty exciter coil (Measure peak voltage ). 7. Faulty ignition coil . 8. Faulty ICM (in case when above no . 1-7 are normal ). 1. lncorrect peak voltage adaptor connections (System is normal if measured

No peak voltage voltage is over the specifications with reverse connections ). 2. Short circuit in ignition switch wire or engine stop switch wire (black/white). 3. Faulty ignition switch or engine stop switch . 4. Loose or poorly connected ICM connectors . 5. Open circuit or poor connection in ground wire (green )of the ICM. 6. Faulty peak voltage adaptor . 7. Faulty exciter coil (measure peak voltage ). 8. Faulty ignition pulse generator (measure peak voltage ). 9. Faulty ICM (in case when above no. 1-8 are normal ).

Peak voltage is norm 1. faulty spark plug or leaking ignition coil secondary current ampere . but spark jumps at p 2. faulty ignition coil .

1. the multimeter is too low ; 10M /DCV. Exciter coil Low peak voltage 2. cranking speed is too slow ( operation force of the kickstarter is weak ).

3. the sampling timing of the tester and measured pulse were dot synchronized (system is normal if measured voltage is over the standard voltage at least once). 4. Faulty exciter coil (in case when above no . 1-3 are normal ). 1. Faulty peak voltage adaptor . 2. Faulty exciter coil .

Ignition 1. The multimeter impedance is too low ; 10M /DCV. pulse Low peak voltage 2. Cranking speed is too slow ( operation force of the kickstarter is weak ). Generator 3. the sampling timing of the tester and measured pulse were dot synchronized

(system is normal if measured voltage is over the standard voltage at least once). 4. Faulty ignition pulse generator (in case when above no . 1-3 are normal ). 1. Faulty peak voltage adaptor . 2. Faulty ignition pulse generator.

IGNITION SYSTEM INSPECTIONNOTE:·If there is no spark at plug ,check all connections forloose or poor contact before measuring each peak voltage.·Use recommended digital multimeter or commercialavailable digital multimeter with an impedance of 10M/DVC minimum.·The display value differs depending upon the internalimpedance of the multimeter.·If using peak voltage tester (U.S.A. only ),follow themanufacture's instructions.

Connect the peak voltage adaptor to the digital multimeter,or use the peak voltage tester TOOLS:peak voltage tester Peak voltage adaptor 07HGJ-0020100(not available in U.S.A.) with commercially availabledigital multimeter (impedance 10M /DCV minimum)

IGNITION COIL PRIMARY PEAK VOLTAGE

△WARNINGAvoid touching the spark plug and tester probes toprevent electric shock.

NOTE:·Check all system connections before inspection if thesystem is disconnected ,incorrect peak voltage might be measured.·Check cylinder compression and check that the sparkplug is installed correctly.

No peak voltage

No peak voltage

Unusual condition

GOOD KNOWN SPARK

PEAK VOLTAGEADAPTOR

DIGITAL

Disconnect the spark plug cap from the spark plug .Connect a known good spark plug to the spark plug cap and ground the spark plug to the cylinder as done in a spark test.

with the ignition coil primary wire connected ,connect the peak voltage adaptor or peak voltage tester probes to the ignition coil primary wire terminal and found .

CONNECTION:Black / yellow terminal (-)-Body ground (+)Turn the ignition switch ON and engine stop switch to "RUN" .

Shift the transmission into neutral .Crank the engine with the kickstarter and read ignitioncoil primary peak voltage .

PEAK VOLTAGE:100V minimumIf the peak voltage is abnormal, follow the checks described in the troubleshooting chart (page 14-2).

IGNITION PULSE GENERATOR PEAK VOLTAGENOTE:Check cylinder compression and check that the spark plug is installed correctly.

Remove the seat assembly (page 2-2) .

Disconnect the 4P connector from the ICM .Connect the peak voltage adaptor or peak voltage testerprobes to the connector terminals of the wire harnessside.

TOOLS:Peak voltage tester Peak voltage adaptor 07HGJ-00210100(not available in U.S.A.) with commercially available digital multimeter (impedance 10M /DCV minimum )

CONNECTIONBlue /Yellow terminal(+) -Green (-)

Shift the transmission into neutral .Crank the engine with the Kickstarter and read the peakvoltage .

PEAK VOLTAGE:0.7V minimum

If the peak voltage measured at ICM connector is abnormal.measure the peak voltage at the pulse generator connector .

Disconnect the ignition pulse generator connector (blue / yellow ) and connect the peak voltage adaptor or tester probes to the connector terminal of the ignitionpulse generator side and ground .In the same manner as at the ICM connector ,measure the peak voltage and compare it to the voltage measuredat the ICM connector .

·If the peak voltage measured at the ICM is abnormaland the one measured at the ignition pulse generator isnormal , the wire harness has an open circuit or loose connection .·If both peak voltages are abnormal .follow the checksdescribed in the troubleshooting chart (page 14-2) .

ALTERNATOR EXCITER COIL PEAK VOLTAGE△WARNINGAvoid touching the spark plug and tester probes to prevent electric shock .

NOTE :Check cylinder compression and check that the spark plugis installed correctly.

Remove the seat assembly (page 2-2)ICM CONNECTORS

EXCITER COIL CONNECTOR

ICMCONNECTOR

IGNITION COIL

Disconnect the 3p and 2p connectors from the ICM .Connect the peak voltage adaptor or peak voltage testerprobes to the connector terminals of the wire harnessside .

TOOLS:Peak voltage tester Peak voltage adaptor 07HGJ-0020100(not available in us. A. ) with commercially available digital multimeter ( impedance 10M /DCV minimum )

CONNECTION :Black /Red terminal (+)-Green (-)

Shift the transmission into neutral .Crank the engine with kickstarter and read the peak voltage

PEAK VOLTAGE :100v minimum

If the peak voltage measured at ICM connector is abnormal ,measure the peak voltage at the alternator exciter coil connector. Disconnect the alternator exciter coil connector (black /red )and connect the peak voltage adaptor or tester probes to the connector terminal of the exciter coil side and ground .In the sane manner as at the ICM connector , measure the peak voltage and compare it to the voltage measuredat the ice connector .

If the peak voltage measured at the ICM is abnormal and the one measured at the alternator exciter coil is normal.the wire harness has an open circuit or loose connection .If both peak voltages are abnormal ,follow the checks described in the troubleshooting chart (page 14-2).

IGNITION COILREMOVAL/INSTALLATIONDisconnect the spark plug cap from the plug .Disconnect the wires from the ignition coil .

Remove the bolt and ignition coil .

Installation is in the reverse order of removal .

TORQUE:6N .m (0.6kgf . M , 4.3 lbf.ft )

IGNITION CONTROL MODULEREMOVAL/INSTALLATION

Remove the seat assembly (page 2-2)

Disconnect the lgnition Control Module (ICM )connectors .Remove the ICM from the frame .

Install action is in the reverse order of removal .

ENGINE STOP SWITCH /IGNITIONSWITCHINSPECTION

Disconnect he switch connectors

Check for continuity between the black / white and green write terminals of the switch side connectors .

There should be continuity with the switch OFF and there should be no continuity when the engine stop switch is RUN or the ignition switch is ON .

IGNITION TIMING△WARNINGWhen the engine must be running to do some work ,make sure the area is well-ventilated .never run the engine in an enclosed area .The exhaust containspoisonous carbon monoxide gas that may cause lossof consciousness and lead to death. Run the engine

EXCITER COIL CONNECTOR

in an open area or with an exhaust evacuation system in an enclosed area .

Warm up the engine .Stop the engine and remove the left crankcase cover (page 10-2).Connect the timing light to the spark plug wire .Start the engine and let it idle .IDLE SPEED :1,700±100rpm

Read the instructions for timing light operation .

The ignition timing is correct the *F*mark aligns with the index notch on the left crankcase .Increase the engine speed by turning the throttle stop screw and make sure the "F" mark begins to moveclockwise .Install the left crankcase cover (page 10-8)

ENGINE DOES NOT START OR IS HARD TO START

Possible cause 1. Check the flue flow to carburetor ————Not reaching carbureto. Clogged fuel line and strainer │ . Clogged fuel tank breathe tube Reaching carburetor ↓ 2. Perform a spark test ———————— Weak or no spark ———————————→ . Faulty spark plug │ . Fouled spark plug Good spark . Faulty ignition control module │ . Broken or shorted spark plug │ wire │ . Faulty ignition pulse generator │ . Faulty engine stop switch or │ ignition switch │ . Loose or disconnected ignition ↓ system wires 3. Remove and inspect spark ———————— W e t ————. Flooded carburetor │ . Choke valve closed G o o d . Air cleaner dirty │ ↓ 4. Start by following normal ——————— Engine starts but . Improper choke operation │ . Carburetor incorrectly adjusted E n g I n e d o e s n o t . Intake pipe leaking │ . Improper ignition timing (faulty │ ignition coil or ignition pulse │ generator ↓ . Fuel contaminated 5. T e s t c y l I n d e r ———————— L o w ——. Valve clearance too small

. Valve stuck open

. Worn cylinder and piston ring

. Damaged cylinder head gasket

. Seized valve

. Improper valve timing

TROUBLESHOOTING

ENGINE LACKS POWER Possible cause

1. Raise wheel off the ground and spin ————— Wheels do not spin freely ——————→ . Brake dragging by hand . Worn or damaged wheel bearing │ Wheels spins freely ↓ 2. Check tire pressure ——————————— low ——————. Faulty tire valve │ . Punctured tire Pressure normal │ ↓ 3. Accelerate rapidly from low ———————— Engine speed doesn't ————————→ . Clutch slipping to second change accordingly . Worn clutch discs/plates │ . Warped clutch discs/plates Engine speed reduced . Weak clutch spring ↓ . Additive in engine oil 4. Accelerate lightly ——————————— Engine speed does n. Choke valve closed │ increase . Clogged air cleaner Engine speed increase . Restricted fuel flow │ . Clogged muffler ↓ . Pinched fuel tank breather tube 5. Check ignition timing —————————— Incorrect ————. Faulty ignition control module │ . Faulty ignition pulse generator Correct │ ↓ 6. Test cylinder compression ———————— Incorrect ————————————→ . Valve clearance too small │ . Worn cylinder and piston rings Normal . Leaking head gasket ↓ . Improper valve timing 7. Check carburetor for clogging ——————— Clogged ————. Carburetor not serviced │ frequently enough Not clogged ↓ 8. Remove spark plug ——————————— Fouled or discolored ———————→ . Plug not serviced frequently │ enough Not fouled or discolored . Spark plug are the incorrect heat ↓ range 9. Check oil level and condition ——————— Incorrect ————. Oil level too high 　　　│ . Oil level too low Correct . Contaminated oil ↓ 10. Remove cylinder head cover ——————— Valve train not lubricated ——————→ . Clogged oil passage and inspect lubrication properly . Clogged oil control orifice　　　│ Valve train lubricated properly　　　│

│ ↓ Possible cause 11. Check for engine overheating —————— Overheating ——. Excessive carbon build-up in │ combustion chamber Not overheating . Use of poor quality fuel │ . Clutch slipping │ . Lean fuel mixture ↓ . Wrong type of fuel 12. Accelerate or run at light speed —————— Engine knocks —. Worn piston and cylinder │ . Wrong type of fuel Engine dose not knock . Excessive carbon build-up in │ combustion chamber ↓ . Lgnition timing to advanced (faulty

ignition control module ). Lean fuel mixture

POOR PERFORMANCE AT LOW AND IDLE SPEED

Possible cause 1. Check carburetor air screw ———— Incorrect —————————. See section 5 adjustment │ Correct │ ↓ 2. Check for leaking intake pipe —— Leaking —————————————————→ . Loose carburetor mounting bolts │ . Damaged insulator . Not leak │ ↓ 3. Perform spark test ———————Weak or intermittent spark —————————→ . Faulty or fouled spark plug │ . Faulty ignition control module │ . Faulty ignition coil │ . Broken or shorted spark plug │ wire │ . Faulty engine stop switch or │ ignition switch │ . Faulty ignition pulse generator │ . Loose or disconnected ignition │ system wires ↓ 4. Check ignition timing ———————— Incorrect ———————. Improper ignition timing ( faulty

ignition control module )

POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Disconnect fuel tube and check the ————— Fuel flow restricted ————————→ . Clogged fuel ling fuel flow . Clogged fuel tank breather tube

. Faulty fuel valve fuel flows freely . Clogged fuel strainer

2. Remove the carburetor and check ————— Clogged ————————————→ . Clean for clogging

Not clogged

3. Check valve timing ——————————— incorrect ————————————→ . Cam sprocket not installed properly

correct

4. Check ignition timing —————————— incorrect ————————————→ . Faulty ignition control module. Faulty ignition pulse generator

correct

5. Check valve spring —————————— weak —————————————→ . Faulty spring

not weak

POOR HANDLING Possible cause

1. If steering is heavy ———————————————————————————→ . Steering stem adjusting nut too tight . Damaged steering head bearings

2. If either wheel is wobbling —————————————————. Excessive wheel bearing play. Bent rim. Improper installed wheel hub . Swingarm pivot bushing excessively worn . Bent frame

3. If the motorcycle pulled to one side —————————————. Faulty shock absorber. Front and rear wheel not aligned. Bent fork . Bent swingarm . Bent axle

Documents

WARNING Indicates a strong possibility of severe personal ... · The symbols used through out this manual show specific service procedures. If supplementary information is required